Electric motor/generator with integrated differential

ABSTRACT

An electrical machine comprising: at least one stator, at least one module, the at least one module comprising at least one electromagnetic coil and at least one switch, the at least one module being attached to the at least one stator; at least one rotor with a plurality of magnets attached to the at least one rotor, an integrated electrical differential coupled to at least one of the rotors, the at least one integrated electrical differential permitting the at least one rotor to output at least two rotational outputs to corresponding shafts, wherein the at least two rotational outputs are able to move the shafts at different rotational velocities to one another. The electrical machine is configured to fit into a housing, and that can be retrofitted into a conventional vehicle by replacing the mechanical differential.

CROSS REFERENCE

This application is a continuation of U.S. application Ser. No.15/297,082, filed Oct. 18, 2016, which is a continuation of U.S.application Ser. No. 14/651,106, filed Jun. 10, 2015, now U.S. Pat. No.9,509,198, issued Nov. 29, 2016, which is the National Phase applicationof International Application No. PCT/AU2013/001438, filed Dec. 9, 2013,which designates the United States and was published in English, andclaims priority to U.S. Provisional Application No. 61/735,379, filedDec. 10, 2012. In addition, this application is related to AustralianProvisional Application No. 2011902310, filed Jun. 10, 2011, andInternational Patent Application No. PCT/AU2012/000655, filed Jun. 8,2012 Each of these priority and related applications, in their entirety,are incorporated herein by reference.

FIELD

This disclosure relates generally electric motors/generators adapted forvarious applications as well as to related methods and/or systems.Certain embodiments of the present disclosure relate to electricmotors/generators which are: 1) reversible, 2) able to efficientlyproduce high torque in portions of the power and/or RPM range, 3) ableto efficiently produced power in portions of the power and/or RPM range,4) able to efficiently produce high torque substantially throughout thewhole of a defined extended power and/or RPM range, 5) able toefficiently produce power substantially throughout the whole of adefined extended power and/or RPM range, 6) are compact, 7) are modular,8) have an integrated differential or 9) combinations thereof. Certainembodiments are able to be employed, for example, as direct-drive wheelmotors, mills and/or regenerative braking.

BACKGROUND

The use of electric motors/generators in a number of application areasis known. For example, in electric vehicles and/or industrial equipment.Traditional electric motors/generators typically work reasonable well atparticular speeds and power requirements. However, as the speed or poweroutput is varied the efficiency of these traditional motors/generatorsdrops. To ensure that the device keeps operating at high efficiency mostdevices are often run at higher speeds even when less would suffice,wasting energy, or are coupled to expensive and heavy transmissionsystems which require ongoing maintenance and greatly increase thenumber of moving parts increasing the risk of failure.

Modifying existing motor drive systems such that they are capable ofVariable Speed Drive (VSD) can introduce energy savings depending on theapplication. However, adding VDS to traditional motors is an expensiveexercise. The power supply's frequency has to be modified, requiringhigh current switching, which use large and expensive electronicswitches. Further once the speed of the motor is adjusted the motor mayno longer be operating at its peak efficiency therefore the energysavings of running the motor slower may be offset by running the motorin a region that is less efficient.

Various configurations of traction electric motors are known. However,for many applications such motors tend to have excessive weight andbulk. Also known is the use of disk-shaped wheel motors, located at orwithin a wheel, and driving directly. At present, the majority oftraction motors used, for example, in hybrid electric vehicles (HEV) andelectric vehicles (EV) are interior permanent magnet synchronousmachines. In common with other synchronous designs, these may sufferfrom conduction and magnetic losses and heat generation during highpower operation. Rotor cooling is more difficult than with brushlessdirect-current motors and peak point efficiency is generally lower.Generally speaking, induction machines are more difficult to control,the control laws being more complex and less amenable to modelling.Achieving stability over a suitable torque-speed range and controllingtemperature is more difficult than with brushless direct-current motors.Induction machines and switched-reluctance machines have been used formany years, but require modification to provide suitable optimalperformance in, for example, HEV and EV applications.

Current state of the art electric vehicle drive trains consist of anelectric battery or generator connected to control electronics, thecontrol electronics modulate the voltage to the required frequency todrive the electric motor, the output of the electric motor is coupled tothe input of a gear set with an integrated differential and the outputis connected to the vehicles half shaft. There is a need for designsthat fit the same size envelope as the differential housing in anexisting petrol powered vehicle and mounted in the existing location asthe existing differential where the output can be directly coupled tothe wheel using the vehicles existing half shafts. This would permit theuse of electric drive trains inside existing vehicles frames withoutredesign and retooling of the existing vehicle subframe and half shafts.

There is a need for improved systems, devices and methods directed toelectric motors/generators. The present disclosure is directed toovercome and/or ameliorate at least one of the disadvantages of theprior art as will become apparent from the discussion herein.

SUMMARY

This summary is meant to be exemplary of certain embodiments. Devices,methods of use, methods of manufacture and/or systems are disclosed inthe specification. Some embodiments may not be disclosed in this summarybut are disclosed in other examples or other portions of thisdisclosure.

Certain embodiments are directed to an electrical machine comprising; atleast one stator; at least one module, the at least one modulecomprising at least one electromagnetic coil and at least one switch,the at least one module being attached to the at least one stator; atleast one rotor with a plurality of magnets attached to the at least onerotor, the at least one rotor has an integrated differential, the atleast one differential permits the rotor to output at least tworotational outputs, wherein the at least two rotational outputs are ableto move at different rotational velocities to each other and wherein theat least one module is in spaced relation to the plurality of themagnets; and the at least one rotor being in a rotational relationshipwith the at least one stator, wherein the quantity and configuration ofthe at least one module in the electrical machine is determined based inpart on one or more operating parameters; wherein the at least onemodule is capable of being independently controlled; and wherein the atleast one module is capable of being reconfigured based at least in parton one or more of the following: at least one operating parameter duringoperation, at least one performance parameter during operation, orcombinations thereof.

Certain embodiments are directed to an electrical machine comprising: atleast one stator; at least one module, the at least one modulecomprising at least one electromagnetic coil and at least one switch,the at least one module being attached to the at least one stator; atleast one rotor with a plurality of magnets attached to the at least onerotor, the at least one rotor has an integrated differential, the atleast one differential permits the rotor to output at least tworotational outputs, wherein the at least two rotational outputs are ableto move at different rotational velocities to each other and wherein theat least one module is in spaced relation to the plurality of themagnets; and the at least one rotor being in a rotational relationshipwith the at least one stator.

Certain embodiments are directed to an electrical machine comprising: atleast one stator; at least one module, the at least one modulecomprising at least one electromagnetic coil and at least one switch,the at least one module being attached to the at least one stator; atleast one rotor with a plurality of magnets attached to the at least onerotor, wherein the at least one module is in spaced relation to theplurality of the magnets; an integrated differential coupled to at leastone of the at least one rotors, the at least one integrated differentialpermitting the at least one rotor to output at least two rotationaloutputs to corresponding shafts, wherein the at least two rotationaloutputs are able to move the shafts at different rotational velocitiesrelative to one another, and the at least one rotor being in arotational relationship with the at least one stator; wherein thequantity and configuration of the at least one module in the electricalmachine is determined based in part on one or more operating parameters;wherein the at least one module is capable of being independentlycontrolled; and wherein the at least one module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, at least one performanceparameter during operation, and combinations thereof. Certain aspectsare directed to the electric machine, wherein the electrical machine isconfigured to fit into a housing and that can be retrofitted into aconventional vehicle by replacing the differential. Certain aspects aredirected to the electric machine, wherein the electrical machine isconfigured to fit into a housing and that can be located insubstantially that same position where a differential would otherwise belocated in a vehicle or other machine. Also disclosed are methods ofusing and manufacturing the embodiments disclosed herein.

Certain embodiments are directed to an electrical machine comprising: aplurality of stators; a plurality of modules comprising at least oneelectromagnetic coil and at least one switch and being attached to atleast one of the plurality of stators; a plurality of rotors with aplurality of magnets attached to at least one of the plurality ofrotors, the plurality of rotors are able to move independently to oneanother to produce a differential output that permits the electricmachine to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocity's relative to one another, andthe plurality of modules are in spaced relation to the plurality of themagnets; and the plurality of rotors being in a rotational relationshipwith the plurality of stators; wherein the quantity and configuration ofthe plurality of modules in the electrical machine is determined basedin part on one or more operating parameters; wherein the plurality ofmodules are capable of being independently controlled, and wherein theplurality of modules are capable of being reconfigured based at least inpart on one or more of the following: at least one operating parameterduring operation, and at least one performance parameter duringoperation. Certain aspects are directed to the electric machine, whereinthe electrical machine is configured to fit into a housing and that canbe located in substantially that same position where a differentialwould otherwise be located in a vehicle or other machine. Certainaspects are directed to the electric machine, wherein the electricalmachine is configured to fit into a housing and that can be retrofittedinto a conventional vehicle by replacing the differential.

Certain embodiments are directed to an electrical machine comprising: aplurality of stators; a plurality of modules comprising at least oneelectromagnetic coil and at least one switch and being attached to atleast one of the plurality of stators; a plurality of rotors with aplurality of magnets attached to at least one of the plurality ofrotors, the plurality of rotors are able to move independently to oneanother to produce a differential output that permits the electricmachine to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocity's relative to one another, andthe plurality of modules are in spaced relation to the plurality of themagnets; and the plurality of rotors being in a rotational relationshipwith the plurality of stators; wherein the quantity and configuration ofthe plurality of modules in the electrical machine is determined basedin part on one or more operating parameters; wherein the plurality ofmodules are capable of being independently controlled, and wherein theplurality of modules are capable of being reconfigured based at least inpart on one or more of the following: at least one operating parameterduring operation, and at least one performance parameter duringoperation; and wherein the electrical machine is configured to fit intoa housing and that can be located in substantially that same positionwhere a differential would otherwise be located in a vehicle or othermachine.

Certain embodiments are directed to an electrical machine comprising: atleast one stator; at least one module, the at least one modulecomprising at least one electromagnetic coil and at least one switch,the at least one module being attached to the at least one stator; atleast one platter or rotor with a plurality of magnets attached to theat least one platter or rotor, wherein the at least one module is inspaced relation to the plurality of the magnets; an integrateddifferential coupled to at least one of the at least one platters orrotors, the at least one integrated differential permitting the at leastone platter or rotor to output at least two rotational outputs tocorresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocities relative toone another, and the at least one platter or rotor being movementrelationship with the at least one stator, wherein the quantity andconfiguration of the at least one module in the electrical machine isdetermined based in part on one or more operating parameters; whereinthe at least one module is capable of being independently controlled;and wherein the at least one module is capable of being reconfiguredbased at least in part on one or more of the following: at least oneoperating parameter during operation, at least one performance parameterduring operation, or combinations thereof.

Certain embodiments are directed to a modular, more flexible, moreadaptable electric motor.

Certain embodiments are directed to an electric motor fitted to anelectric car that increases the battery life 10%, 20%, 30%, 40%, 50%,60%, 70% or more.

Certain embodiments are directed to electrical motors that are smallerand/or lighter than similar competing electric motors in the same class.Because of its small size and sufficient power to weight ratio it opensa plethora of options in terms of where to mount the motor. For example,in a vehicle an electric motor with the same, substantial the same,similar or sufficient power and wheel as a existing internal combustionmotor and drive train could be designed, and yet the electric motor willfit the existing size envelope, or substantially the existing sizeenvelope, as the differential housing in an existing petrol poweredvehicle and can be mounted in the existing location, or substantial thesame location, as the existing differential. In other words, certaindisclosed embodiments permit the replacement or substitution of acombustion motor and drive train for powering the vehicle with a smalllight direct drive electric motor that has similar or improved poweroutputs to the combustion motor and yet can be placed where the existingdifferential is located. The output can be directly coupled to the wheelusing the vehicles existing half shafts. This permits the use ofelectric drive trains inside existing vehicles frames without redesignand retooling of the existing vehicle subframe and half shafts.

Certain embodiments may be used to extend an existing internalcombustion vehicle production line by adding an additional electricmotor variant to the assembly line. For example at the junction point ofthe production line where different chassis are diverted to differentengine size lines, an additional line could be added where instead ofinstalling a differential the technology disclosed herein is installedin the existing location using the existing mounting points. A wire maythen be run from the battery pack to the power supply.

To retrofit a vehicle the drive train consisting of the internalcombustion engine, transmission, differential can be removed from thevehicle and replaced by the electric motor onto the existing mountingpoints as the existing differential. The half shafts may then beconnected, and wires from a battery pack that could be fitted to theprevious location of the internal combustion engine and transmission.

A comparison between certain embodiments of the present disclosureextending an existing internal combustion engine production line againstother state of the art electric drive trains where the chassis' bodywould require modification could result in estimated savings of 100s ofmillions of US dollars.

A comparison between the certain embodiments of the present disclosureand other state of the art electric drive trains not including thebatteries could reduce the weight of the drive train by 10%, 25%, 35%,50%, 60%, 75% or more. For example, the GM Holden EV Commodorepreproduction vehicle's drive train not including the battery weighs inclose to 100 kg. Certain embodiments of the present disclosure wouldsave approximately 60 kg. Certain embodiments would only introduce onedirectly swappable part to the drive train assembly line (the motor),while the exiting EV Commodore preproduction vehicle would introduce atleast 9.

A comparison between the certain embodiments of the present disclosureand Tesla's current electric motor indicates that certain embodimentshave double the power to weight ratio. Substantial further weightsavings are made as there is no, or less requirement for the motorcontroller and gearbox. Certain embodiments have a power to weight ratiothat is 25%, 50%, 100%, 125%, 150%, 200%, 250%, or 300% greater than abrushless permanent magnet three phase electrical machine with asubstantially similar size and weight.

In certain embodiments, existing internal combustion vehicles may beconverted to hybrid drives by attaching the at least one rotor to atleast one crown wheel that is driven by at least one drive shaft. Thecrown wheel could alternatively be machined as part of the magneticrotor. During internal combustion operation the drive shaft turns thecrown wheel. During electric drive the drive shaft is disengaged and thevehicle is propelled by the coils. The coils can also be driven at thesame time, or substantially same time, as the drive shaft to increaseacceleration performance.

In certain embodiments, a typical arrangement of brushless, axial-fluxelectric motor comprises one or more rotors in the form of circularplates (these may be substantial flat, disk-shaped) rotationallysupported on a differential, which may consist of an epicyclic geartrain, that permits two outputs to rotate at different speeds, the rotorhaving a circular array of high energy permanent magnets embedded aroundits periphery with alternating polarity, the axes of the magnets beingparallel to the shaft; one or more stators in the form of circularplates fixed parallel to the rotors and separated by a small air gap,each the stator having a circular array of electromagnetic coilsembedded around its periphery on the same centre diameter as themagnets; sensing ways (or means) to detect absolute position androtational speed of the rotors; and a control system which, in responseto inputs from the sensing ways (or means) and power and rotationaldirection commands, energises the magnetic coils to attract and repelthe magnets for the purpose of generating rotary motion. One advantageof certain configurations are its high power and/or torque density, themagnitude of torque generated being proportional to the strength of themagnetic flux generated by the coils, the strength of the magnetic fluxof the permanent magnets, the effective diameter of the coil and magnetarrays and the gap between them. At the same time, the use of electroniccommutation to control the current flows to individual stator coilsconfers high energy efficiency over a wide power and RPM range,resulting in essentially flat efficiency curves.

Certain embodiments of the present disclosure are directed toconfigurations of brushless, axial-flux, direct-current electric motorswhich have one or more of the following characteristics: high powerand/or torque densities; which combines rapid acceleration with anextended RPM range; which has low weight and/or compact form, making itsuitable for a variety of applications; which employs complex controlmechanisms (or means) to obtain high efficiency throughout the desiredrange of operational parameters; which has minimal cooling requirements;which is robust and mechanically and electrically reliable; which iscapable of being manufactured through the assembly of standardcomponents in a range of configurations suitable for employment invehicles from automobiles to heavy trucks and machinery; able tooptimise driving and regenerative efficiency throughout a range ofhighly variable driving and generating conditions and which may bemanufactured at a competitive cost.

According to certain embodiments, a brushless, axial flux,direct-current electric motor comprises: one or more disc-shaped statorsaround the periphery of which a circular array of equally-spaced (orsubstantially equally spaced) electromagnetic coils may be embedded; oneor more disc-shaped rotors around the periphery of which a circulararray of equally-spaced (or substantially equally spaced) magnets may beembedded, the array having the same, or substantially the same centrediameter as that of the electromagnetic coils and the magnets havingalternating pole orientation; the rotors being rotationally supportedparallel (or substantially parallel) to the stators with an air gapbetween them. The central parts of the stators may be cut away to permitthe passage therethrough of a differential, which may consist of anepicyclic gear train, that permits two outputs from the rotor to rotateat different speeds, supporting the rotors and the circuit boards aresupported from the stators concentrically with the shaft, the circuitboards may incorporate solid-state switches which may be activated bycommand signals from a control system to power the electromagnetic coilsto cause the rotors to rotate. In certain embodiments, one or moresensor may be provided to generate signals relating to the absolute andinstantaneous positions of the rotors. In certain embodiments, one ormore sensor may be provided to generate signals relating to thesubstantially absolute and/or substantially instantaneous positions ofthe rotors. In certain embodiments, the permanent magnets aresufficiently powerful and may be of the rare earth type and theelectromagnetic coils are of a form generating high levels of magneticflux, but having low magnetic reluctance permitting rapid switching orreversal of polarity. In certain embodiments, the permanent magnets maybe sufficiently powerful and/or may be of the rare earth type whereinthe one or more of the electromagnetic coils are of a form generatingsufficiently high levels of magnetic flux. In certain embodiments,permanent magnets and/or electromagnetic coils of conventional form areoptionally employed in electric motors for lower cost applications orthose required to meet different operational parameters. Electricalcurrent may be supplied to the solid-state switches via the structure ofthe stators, thereby permitting a heavy current flow to the solid-stateswitches with minimal losses, and the embedding of the electromagneticcoils in the stators permits efficient conductive cooling. In certainembodiments, electrical current may be supplied to the solid-stateswitches via the structure of the stators, thereby permitting a suitablyheavy current flow to one or more of the solid-state switches withsuitably minimal losses, and the embedding of the electromagnetic coilsin the stators permits suitable efficient conductive cooling. Thepositioning of the switches immediately adjacent the electromagneticcoils provides conduction paths of low resistance with minimal losses.In certain embodiments, the positioning of the switches adjacent (orsubstantially adjacent) one or more of the electromagnetic coilsprovides conduction paths of suitably low resistance with suitablyminimal losses. In certain embodiments, the positioning of the switchesabove the rotor reduces the external circumference of the motor toensure a small packaging fit while maintaining a suitably low resistancewith suitably minimal losses. In certain embodiments, the combination ofone or more of the features provides an electric motor of high powerdensity and/or one able to operate efficiently over an extended RPMrange. In certain embodiments, the control system of the direct currentelectric motor may be made to be continuously adaptive, utilisingcomplex logic to determine the most efficient mode of operation inrelation to prevailing operational parameters. In certain embodiments,the control system of the direct current electrical machine may besufficiently continuously (or substantially continuously) adaptive,utilising logic to determine or estimate the appropriately efficientmode of operation in relation to one or more prevailing operationalparameters.

Certain embodiments are directed to an electrical machine, wherein theelectrical machine is a compact direct drive electric motor thatgenerates sufficient or improved propulsion in a wheeled vehicle and theelectric motor and the differential can fit the size of envelope ofexisting differentials in a conventional combustion engine drivenvehicle.

Certain embodiments are directed to an electrical machine, wherein theelectrical machine is a compact direct drive electric motor thatgenerate sufficient or improved propulsion of a wheeled vehicle and theelectric motor and the differential can be installed in line with adrive axial while providing adequate clearance from a road withoutsubstantial modification to an existing suspension of the wheeledvehicle.

Certain embodiments are directed to an electrical machine, wherein theelectrical machine is a compact direct drive electric motor thatgenerate sufficient propulsion of a wheeled vehicle and the electricmotor and the differential can be installed in line with one or moredrive axels while providing adequate clearance from a road withoutsubstantial modification to an existing suspension of the wheeledvehicle.

Certain embodiments are directed to an electrical machine, wherein theelectrical machine is a compact direct drive electric motor thatgenerate sufficient propulsion of a wheeled vehicle and the electricmotor and the differential can be installed in line with one or moredrive axels without lower, or substantially lowering, the clearance froma road and without substantial modification to an existing suspension ofthe wheeled vehicle.

Certain embodiments are directed to an electrical machine, wherein theat least one stator is a substantial portion of the stators contained inthe electrical machine. Certain embodiments are directed to anelectrical machine, wherein the at least one stator is all of thestators contained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theat least one module is a substantial portion of the modules contained inthe electrical machine. Certain embodiments are directed to anelectrical machine, wherein the at least one module is all of themodules contained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theat least one electromagnetic coil is a substantial portion of theelectromagnetic coils contained in the electrical machine. Certainembodiments are directed to an electrical machine, wherein the at leastone electromagnetic coil is all of the electromagnetic coil contained inthe electrical machine.

Certain embodiments are directed to an electrical machine, wherein theat least one switch is a substantial portion of the switches containedin the electrical machine. Certain embodiments are directed to anelectrical machine, wherein the at least one switch is all of theswitches contained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theat least one rotor is a substantial portion of the rotors contained inthe electrical machine. Certain embodiments are directed to anelectrical machine, wherein the at least one rotor is all of the rotorscontained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theplurality of magnets is a substantial portion of the magnets containedin the electrical machine. Certain embodiments are directed to anelectrical machine, wherein the plurality of magnets is all of themagnets contained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theplurality of magnetic induction loops is a substantial portion of themagnetic induction loops contained in the electrical machine. Certainembodiments are directed to an electrical machine, wherein the pluralityof magnetic induction loops is all of the magnetic induction loopscontained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theplurality of magnetic reluctance projections is a substantial portion ofthe magnetic reluctance projections contained in the electrical machine.Certain embodiments are directed to an electrical machine, wherein theplurality of magnetic induction loops is all of the magnetic inductionloops contained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theplurality of stators is a substantial portion of the stators containedin the electrical machine. Certain embodiments are directed to anelectrical machine, wherein the plurality of stators is all of thestators contained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theplurality of modules is a substantial portion of the modules containedin the electrical machine. Certain embodiments are directed to anelectrical machine, wherein the plurality of modules is all of themodules contained in the electrical machine.

Certain embodiments are directed to an electrical machine, wherein theplurality of rotors is a substantial portion of the rotors contained inthe electrical machine. Certain embodiments are directed to anelectrical machine, wherein the plurality of rotors is all of the rotorscontained in the electrical machine.

BRIEF DESCRIPTION OF THE FIGURES

These and other features, aspects, and advantages of the presentdisclosure will become better understood with regard to the followingdescription, appended claims, and accompanying figures where:

FIG. 1 is a schematic showing the geometric properties of a magnet shapeplaced in a circular array, according to certain embodiments.

FIG. 2 is a schematic showing the geometric properties of a circularmagnet shape placed in a circular array, according to certainembodiments.

FIG. 3 is a side view of an electrical machine that is made up of twoelectrical machines that are back to back and share a common rotorshaft, according to certain embodiments.

FIG. 4 is a side view of the electrical machine illustrated in FIG. 3but these embodiments share a common magnet rotor.

FIG. 5 is a graph that shows how the total magnet count decreases as thenumber of coil stages increases, according to certain embodiments.

FIG. 6 is a graph torque comparison, according to certain embodiments.

FIG. 7 is a graph comparing the power losses due to electricalresistance of certain embodiments.

FIG. 8 illustrates a gap in the conductive region of the stator,according to certain embodiments.

FIG. 9 is a partially cut-away view of the electromagnetic coils,according to certain embodiments of the present disclosure.

FIG. 10 illustrates a cross section view of a rotor platterconfiguration according to certain embodiments.

FIG. 11 illustrates a cross section view of two rotor plattersconfiguration according to certain embodiments.

FIG. 12 illustrates a cross section view of a three rotor plattersconfiguration according to certain embodiments.

FIG. 13 is a face view of a rotor of the electric motor of FIG. 10,according to certain embodiments.

FIG. 14 shows a schematic top view of a rotor platter and coilconfiguration, according to certain embodiments.

FIG. 15 shows a perspective view of the configuration of FIG. 14.

FIG. 16 shows in side view an example of the magnetic field linesbetween two magnetic rotors and one coil platter, without end caps,according to certain embodiments.

FIG. 17 shows in side view an example of the magnetic field linesbetween two magnetic rotors and one coil platter, with ferrous steel endcaps, according to certain embodiments.

FIG. 18 shows an example of the magnetic field lines between twomagnetic rotors and one coil platter, with the top rotor consisting ofmagnets aligned in a Halbach array, according to certain embodiments.

FIG. 19 shows an example of a H-bridge switch topology that may be usedwith certain embodiments.

FIG. 20 illustrates an exemplary Motor Control Unit (MCU), Coil ControlUnit (CCU), coil driver controller architecture, according to certainembodiments.

FIG. 21 illustrates a CCU's architecture, according to certainembodiments.

FIG. 22 shows one or more individual MCUs and CCUs in a 1:1:1configuration, according to certain embodiments.

FIG. 23 shows switches controlled by one CCU, with the one CCU beingcontrolled by one or more MCU in a 1:1:n configuration, according tocertain embodiments.

FIG. 24 shows switches controlled by CCUs, with the CCUs beingcontrolled by one or more MCU in a 1:m:n configuration, according tocertain embodiments.

FIG. 25 shows an exemplary controller configurations, whereby switchesare controlled directly by one or more MCUs in a 1:n configuration

FIG. 26 illustrates a CCU without the need for a master controller,according to certain embodiments.

FIG. 27 shows a configuration where a single motor control unit isconnected to a common communication bus, which is connected to one ormore of the coil control units, according to certain embodiments.

FIG. 28 shows a configuration where multiple motor control units areconnected to a common communication bus, which is connected to one moreof the coil control units, according to certain embodiments.

FIG. 29 illustrates a configuration wherein each coil control unit isconnected directly to some or all other coil control units, according tocertain embodiments.

FIG. 30 illustrates a configuration wherein a central communication bus(token ring) is used, according to certain embodiments.

FIG. 31 illustrates a configuration with three redundant communicationbuses, according to certain embodiments.

FIG. 32 is a longitudinal cross-sectional view through an electric motormade in accordance with certain embodiments.

FIG. 33 is an exploded view of the electric motor in FIG. 32.

FIG. 34 illustrates an isometric view of the circuit boards illustratedin FIG. 32 mounted in an electrical machine, according to certainembodiments.

FIG. 35 is a face view of a rotor of the electric motor of FIG. 32.

FIG. 36 is a schematic diagram of the electrical and electronic systemsof the electric motor of FIG. 32.

FIG. 37 illustrates the electrical machine detailed in FIG. 33. Suitableapplications include traction motors in vehicles attached in place ofthe differential, according to certain embodiments.

FIG. 38 is a top view of a rear wheel drive vehicle illustrating alocation of the electrical machine, according to certain embodiments.

FIG. 39 is a top view of a front wheel drive vehicle illustrating alocation of the electrical machine, according to certain embodiments.

FIG. 40 is a top view of an all wheel drive vehicle illustrating alocation of the electrical machine, according to certain embodiments.

FIG. 41 is a top view of a semi-trailer truck illustrating a location ofthe electrical machine, according to certain embodiments.

FIG. 42 is an exploded view of an electric machine, according to certainembodiments.

FIG. 43 illustrates an isometric view of the circuit boards illustratedin FIG. 42.

FIG. 44 is an exploded view of the stator illustrated in FIG. 42.

FIG. 45 illustrate four ways of stacking electrical laminates, accordingto certain embodiments.

FIG. 46 illustrate various coils using a variety of conductor windingtypes, according to certain embodiments.

FIG. 47 illustrates a thinner section of the coil that may be includedin certain embodiments.

FIG. 48 illustrates a pair of cores connected at the bottom such thatthe connectors are both at the top, according to certain embodiments.

DESCRIPTION

The present disclosure will now be described in detail with reference toone or more embodiments, examples of which are illustrated in theaccompanying drawings. The examples and embodiments are provided by wayof explanation and are not to be taken as limiting to the scope of thedisclosure. Furthermore, features illustrated or described as part ofone embodiment may be used by themselves to provide other embodimentsand features illustrated or described as part of one embodiment may beused with one or more other embodiments to provide a furtherembodiments. It will be understood that the present disclosure willcover these variations and embodiments as well as other variationsand/or modifications. It is also to be understood that one or morefeatures of one embodiment may be combinable with one or more featuresof the other embodiments. In addition, a single feature or combinationof features in certain embodiments may constitute additionalembodiments.

The features disclosed in this specification (including accompanyingclaims, abstract, and drawings) may be replaced by alternative featuresserving the same, equivalent or similar purpose, unless expressly statedotherwise. Thus, unless expressly stated otherwise, each featuredisclosed is one example of a generic series of equivalent or similarfeatures.

The subject headings used in the detailed description are included onlyfor the ease of reference of the reader and should not be used to limitthe subject matter found throughout the disclosure or the claims. Thesubject headings should not be used in construing the scope of theclaims or the claim limitations.

Certain embodiments are directed to electrical motors that are smallerand/or lighter than similar competing electric motors in the same classand yet have sufficient power output to replace the combustion motorthat would otherwise be used to power the machine or vehicle. Because ofits small size and sufficient power to weight ratio, the electric motorsdisclosed herein allow the same or a similar machine or vehicle to bepowered at the same, similar or substantial the same performancecharacteristics. For example, an electric motor with the same,substantial the same, similar or sufficient power and wheel torque as anexisting internal combustion engine and drive train is disclosed incertain embodiments herein and yet the electric motor will fit theexisting size envelope, or substantially the existing size envelope, asthe differential housing in an existing petrol powered vehicle andmounted in the existing location, or substantial the same location, asthe existing differential. In other words, certain disclosed embodimentspermit the replacement or substitution of a combustion motor forpowering the vehicle with an small light direct drive electric motorthat has similar power outputs to the combustion motor and yet can beplaced where the existing differential is located. The output can bedirectly coupled to the wheel using the vehicles existing half shafts.This permits the use of electric drive trains inside existing vehiclesframes without redesign and retooling of the existing vehicle subframeand half shafts.

Certain embodiments are directed to compact direct drive electric motorsthat generate sufficient or improved propulsion of the wheeled vehiclewherein the electric motor and the differential can fit the size ofenvelope of existing differentials in a conventional combustion enginedriven vehicle.

Certain embodiments are directed to compact direct drive electric motorsthat generate sufficient or improved propulsion of the wheeled vehiclewherein the electric motor and the differential can be installed in linewith the drive axial while providing adequate clearance from the roadwithout substantial modification to the existing suspension of thewheeled vehicle.

Certain embodiments are directed to a compact direct drive electricmotor that generate sufficient propulsion of the wheeled vehicle,wherein the electric motor and a differential can be installed in linewith one or more the drive axels while providing adequate clearance fromthe road without substantial modification to an existing suspension ofthe wheeled vehicle.

Certain embodiments are directed to a compact direct drive electricmotor that generate sufficient propulsion of the wheeled vehicle,wherein the electric motor and a differential can be installed in linewith one or more drive axels without lower, or substantially lowering,the clearance from the road and without substantial modification to anexisting suspension of the wheeled vehicle.

Certain embodiments consist of a stator and a rotor which may becontained in an enclosure. The rotor creates a magnetic field in thevicinity of the stator; the stator creates a disturbance in the magneticfield forcing the rotor to move to a position that minimizes thedisturbance in the magnetic field. The rotor may consist of a series ofpermanent magnets attached to a differential. The stator may consist ofa series of coils, attached to an enclosure. The enclosure may housebearings to ensure that the rotor can rotate to minimize the disturbancein the magnetic field. Certain embodiments are directed to an electricalmachine comprising: at least one rotor, a plurality of magnets used in,or in contact with, the rotor, at least one stator and a plurality ofcoils used in, or in contact with, the stator, wherein the configurationis contain, partially contained within and a enclosure; and a controlelectronics provides individual control over each coil and/or cluster ofcoils generating the disturbances. In certain embodiments, the controlelectronics provides individual control over one or more coils and/orone or more cluster of coils generating the disturbances. In certainembodiments, the control electronics provides individual control over atleast 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% of the coils or at least40%, 50%, 60%, 70% 80%, 90%, 95% or 100% of the cluster of coilsgenerating the disturbances.

Certain embodiments are directed to an electrical machine that providessignificant size, weight reduction, price reduction, or combinationsthereof, while increasing the electrical machine's power output,efficiency, reliability, maintainability or combinations thereof. Alsodisclosed are methods of using the electrical machine, methods ofmanufacturing the electrical machine and/or systems that incorporate theelectrical machine.

Certain embodiments are directed to adaptive magnetic flux arrayswherein the device, methods, and/or systems permit real time, orsubstantially real time, software reconfigurable electricalmotor/generator. The disclosed devices, methods and/or systems may beused as both a motor and a generator may also be referred to as anelectrical machine. One advantage of certain embodiments is the abilityof those embodiments to reconfigure itself in real time, orsubstantially real time, this permits the machine, method and/or systemto find its optimal settings across very wide operating speeds and/orloads. Such flexibility results in energy savings across a plethora ofindustries. Other advantages of certain embodiments disclosed hereinare: reduce cost by reducing the amount of copper in the windings; theamount of electrical steel; the size of the package required to house itor combinations thereof.

For example, the weight of the copper windings in an electrical machineis proportional to the size of current, greater the current the heavierthe wire. This relationship is quadratic, not linear. Certainembodiments effectively divide and conquer this relationship. In certainembodiments each (or one or more) independent coil handles relativelysmall amounts of current. By using numerous small coils, the overallcurrent through each coil (or one or more) remains low, but the totalcurrent for the whole system scales linearly, along with the quantity ofmaterial and/or the cost of the electrical machine. By overcoming thisquadratic relationship much larger electrical machines may be built atmore affordable prices.

For example, a traditional 3 phase 300 kw electrical machine operatingoff a 415 v supply requires a current through each phase of the coil of240 amps. In one exemplary embodiment, the windings are distributedacross 34 coils, the current per coils is 21 amps. To have the same,substantially the same, or similar, resistive power loss through the twoconfigurations, the traditional electrical machine requires about 10times the weight of wire. Certain embodiments are directed to anelectrical machine wherein the resistive power loss is substantially thesame as the resistive power loss of a traditional electrical machine butthe electrical machine requires at least 500, 400, 300, 250, 200, 150,100, 75, 50, 25, 20, 10, 5 or 2 times less weight of wire. Certainembodiments are directed to an electrical machine that usessubstantially less copper wherein the resistive power loss issubstantially the same as the resistive power loss of a similar machinewith fewer coils. The copper saved is proportional to the number ofcoils cn the embodiment contains compared to the number of coilscontained in a comparable machine dn. The potential savings are up to dndivided by cn times the copper. In certain embodiments, the electricalmachine requires between 500 to 100, 100 to 300, 50 to 100, 150 to 250,300 to 250, 225 to 175, 150 to 75, 75 to 50, 50 to 25, 20 to 10, 15 to5, 2 to 5 times less the weight heavier of wire as compared with abrushless permanent magnet three phase electrical machine with similarpower.

In the example, above as there is 10 times less wire, the volume of ironcore required to wrap the wire around is decreased. Subsequently theentire unit can fit into a substantially smaller enclosure furtherreducing the mass of materials. High currents still need to betransferred from the devices power input to the coils. If the body ofthe electrical machine is constructed from a good conductor such asaluminium, the body can be used as the conductor, further reducing themass of materials used. In this example, the exemplary electricalmachine disclosed herein reduces the weight of a 300 kw electricalmachine from many hundreds of kilograms to about 34 kilograms. Certainembodiments disclosed herein provide an electrical machine that mayproduce substantially the same power output of a traditional electricalmachine but with a weight that is reduced by at least 95%, 90%, 85%,80%, 70%, 60%, 50%, 40%, 30%, or 20%. Certain embodiments disclosedherein provide an electrical machine that may produce substantially thesame power output of a traditional electrical machine but with a weightthat is reduced by between 95% to 20%, 90% to 70%, 85% to 60%, 90% to50%, 80% to 40%, 70% to 50%, 60% to 30%, 50% to 20%, 40% to 20% or 30%to 20%.

Another advantage of certain embodiments is the ability to independentlycontrol each coil, when less torque is required or available, sectionsof the electrical machine may be powered down. In certain embodimentsthe ability to independently control one or more coils, when less torqueis required or available, then sections of the electrical machine may bepowered down. Certain embodiments are directed to an electrical machinewith the ability to independently control one or more coils. Certainembodiments are directed to an electrical machine with the ability toindependently control one or more coils. Certain embodiment are directedto an electrical machine with the ability to independently control atleast 70%, 80%, 90%, 95%, 98% or 100% of one or more coils in aplurality of coils. Certain embodiment are directed to an electricalmachine with between 10 to 100, 20 to 50, 50 to 200, 20 to 60, 30 to 80,or 30 to 60 coils wherein the electrical machine is configured toindependently control at least 70%, 80%, 90%, 95%, 98% or 100% of thecoils. Because certain disclosed embodiments have numerous coils,substantially finer control over optimising the efficiency of themachine is available.

Traditional electrical machines control their peak efficiency by varyingthe timing of the switching between phases of their coils. As the timingis traditionally set at assembly or installation either by the brushesor the frequency of the drive circuit, variations of velocity and powerreduces the peak efficiency of the electrical machine. Another advantageof certain embodiments is that they may be configured to continuouslyoptimize the timing of the coils, this can provide efficiency savings ofup to, for example, 40% when summed over the entire operating region ofa comparatively powered electrical machine. Certain embodiments may beconfigured to optimize the timing of a plurality of coils substantiallycontinuously, sufficiently continuously, continuously, non-continuously,or intermediately. In certain embodiments the ability to optimize thetiming of a plurality of coils substantially continuously, sufficientlycontinuously, continuously, non-continuously, or intermediately providesan efficiency savings of up to 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%,50% or 60% when summed over the entire operating region of acomparatively powered electrical machine.

In an axial configuration, certain embodiments of the present disclosuremay reduce the total number of permanent magnets by a minimum of 25%.The total saving percentage increases with the number of rotorsrequired. This may be achieved by the sharing of common rotors, makinguse of both sides of a rotors magnetic fields rather than one. Forexample, in a two stator, 4 rotor motor, one rotor is eliminated for asaving of 25%. For 6 stator, 12 rotor motor, 5 rotors are eliminated fora saving of 41%. In certain embodiments, the total number of permanentmagnets may be reduced by a minimum of 10%, 15%, 20%, 25%, 30%, 35%,40%, 45%, 50%, 55%, 60% or 70% and still provide comparable poweroutput.

Certain embodiments of the present disclosure may accommodate magnets ofvarious shapes. For example, the shape may be a cylinder, cuboid,segmented, trapezoidal or other suitable shapes.

For smooth torque a sinusoidal application of force may be suitable.Through the use of the interleaved coil design of certain disclosedembodiments it is possible to create a smooth sinusoidal output usingcylindrical magnets. A further consequence of the interleaved coildesign is reduced magnet volume. Most axial flux motors use trapezoidalmagnets, which for a given diameter, or trapezoidal height, occupy andrequire more magnetic volume. For a trapezoidal with long edge length40, short 15 and height 25, vs. a circular magnet of diameter 25, avolumetric saving of 29.24% is achieved. Minimal saving occurs when thetrapezoidal shape approaches a square, giving a minimum reduction ofapproximately 21%. Certain embodiments may be configured in a circulararray, or substantially circular array, such that the electrical machinehas one more set of magnets than coils, the coils can be powered in sucha sequence that the torque generated by the electrical machine issufficiently smooth. Ensuring that there is little variation in torqueduring start up ensures smooth acceleration at low speeds. For example,an embodiment that comprises a 17 coil circular array has about 30 timesless variation in torque through a rotation than a 3 phase equivalent.Certain embodiments comprising a plurality of coils in at least onecircular array has 50, 40, 35, 30 25, 20, 15, 10 or 5, times lessvariation in torque through a rotation than a 3 phase equivalent.

Magnet Volume Reduction

In regards to efficiency the ideal switching waveform inside a coil is asine wave. The sine wave has only one frequency component, thefundamental frequency, ensuring that higher frequency harmonics may notbe contained in the signal. An ideal square wave may be made up of thefundamental frequency (the frequency of the square wave) plus aninfinite sequence of higher frequency harmonics contained in its Fourierseries. There are a number of drawbacks in terms of high frequencyharmonics. High frequency signals tend to travel along the outer edge ofthe conductor known as the skin effect. The higher the frequency thecloser to the skin the signal travels. The resistance of a wire isproportional to the cross sectional area where the electrons aretravelling.

The resistance of the wire is therefore proportional to the frequencythrough that wire. Further high frequency signals tend to radiate awayfrom the device causing interference to other devices. These radiatedeffects need to be contained and filtered to pass CE, FCC, C-tick andother compliance standards. Circular magnets coupled with theinterleaved coil design create a nice sine wave output. A consequence ofcylindrical magnets is reduced total magnet volume, now referring toFIG. 1 we have: Volume of trapezoidal magnet:

${V_{trap} = {\left( \frac{a + b}{2} \right)c\; d}};$d=magnet thickness

Volume of circular magnet: V_(circ)=πr²d; Noting: 2r=C and given theratio of a:b is sufficient such that the trapzoidal perimeter does notintersect the circular perimeter.

Now referring to FIG. 2 we have: Volume saving per coil:

V_(saving) = V_(trap) − V_(circ)$V_{saving} = {{\left( \frac{a + b}{2} \right)c\; d} - {{\pi\left( \frac{c}{2} \right)}^{2}d}}$Alternatively:

$V_{{saving}_{\%}} = {{\left( {1 - \frac{V\;{circ}}{V\;{trap}}} \right) \times 100} = {\left( {1 - \frac{\pi\; c}{2\;\left( {a + b} \right)}} \right) \times 100}}$

In certain embodiments, this saving can be substantial, for example ifwe compare two 25 mm thick rotors, one containing a cylindrical magnetof a diameter of 25 mm and once containing a trapezoidal magnet witha=30, b=20, c=25 the material savings in the cylindrical magnet would be21.46%. In certain embodiments, the material savings in the magnetswould be at least 10%, 15%, 20%, 30%, 40%, 50%, or 60%. In certainembodiments, the material savings in the magnets would be between 10% to60%, 15% to 25%, 15% to 40%, 20% to 60%, 20% to 35%, 30% to 60% or 35%to 55%. In certain embodiments, the savings may be calculated asfollows:

$V_{{saving}_{\%}} = {{\left( {1 - \frac{\pi\; 25}{2\left( {30 + 20} \right)}} \right) \times 100} = {{{\left( {1 - \frac{\pi\; 25}{100}} \right) \times 100}\;\therefore V_{{saving}_{\%}}} = {21.46(\%)}}}$

In regards to peak power, more power may be transferred in a square wavethan in a sine wave. The effective power that may be imparted into thecoil by a sine wave is 1 divide by a square root of 2 (approximately ⅔)while the effective power of a square wave is 1. In terms of theeffectiveness of the mechanical energy that can be converted by a squarewave vs. a sine wave is dependent at least in part on the design of thecoils and the magnets.

Magnets Saving Through Shared Platter Stacks

In certain embodiments, the device may be extended to provide more powerby connecting two motors back to back as illustrated in FIG. 3. A weightand/or cost saving may be achieved by sharing of rotors as illustratedin FIG. 4. In this example, the total number of magnets is reduced bysharing the inner rotors, segments 1 and 2, combining them into onerotor, segment 3. Further, only the outer platters, segments 4 and 5require back irons to contain the magnetic field inside the device, asopposed to the unshared configuration which requires all rotors to beshielded (a total of 4 plates). Typically, the back irons are heavy andthus there is a substantial weight saving through sharing inner rotors.Further the device is more compact, saving the mass of the associatedmaterials. In other words: Total number of magnets (unshared):n _(total) _(unshared) =n _(platters) ×m; m=number of magnets perplatter

Total number of magnets (shared centre rotor platter):

$n_{{total}_{shared}} = {\left( {n_{unshared} - \left( {\frac{n_{unshared}}{2} - 1} \right)} \right) \times m}$

Left figure:n _(total) _(unshared) =4×17; Assuming 17 magnets per plattern _(total) _(unshared) =68

Right figure:

$n_{{total}_{shared}} = {\left( {4 - \left( {\frac{4}{2} - 1} \right)} \right) \times 17}$n_(total_(shared)) = 51

FIG. 5 is a graph that illustrates the reduction in the number ofmagnets when common magnetic rotors are shared between multiple stators.This example is based on rotors with 18 magnets, but the general trendshold true for a range of embodiments. The x axis illustrates the numberof stators, and the Y axis indicates the number of magnets. A comparisonis made between a configuration sharing common internal rotor platters6, to a configuration without shared rotor platters 7. It illustratesthat there are significant saving in the number of magnets required, andthus cost, space and weight savings, when the platters are shared. Thissaving tends linearly towards almost 50% or more platters are used.

Torque Smoothing

A traditional motor with only a single phase supply is only able toapply peak power to the shaft twice per rotation. A basic comparisonbetween motor configurations may be used by assuming the resultingrotational torque is proportional to the sine of the angular differenceof the coils to the permanent magnets (τ α sin(F))

In this exemplary embodiment it is assume that for the number of phasesin a motor, the power applied is constant. As the numbers of phases inthe motor are increased, the power is distributed and applied moreevenly. For a three phase motor, it provides maximum power and torque tothe shaft 6 times per rotation. Its maximum instantaneous power is lessthan the single phase motor. Since certain embodiments of the presentdisclosure may have at least 17 to 1024 independently controllablephases. Certain embodiments may have between 17 to 1021, 19 to 1181, 29to 109, 53 to 127, 89 to 257, 211 to 331, 199, to 577, 433 to 751, 577to 1051, 613 to 757, 619 to 919, 773 to 857, 787 1021 or 811 to 1283independently controllable phases. Certain embodiments may have between10 to 1050, 20 to 40, 30 to 50, 50 to 1200, 75 to 150, 200 to 500, 400to 1200, 600 to 900 or 700 to 1100. This distributes power more evenlythroughout a single rotation and results in smooth torque being appliedto a load.

A simple comparison of maximum producible instantaneous torquethroughout a motors rotation is presented in FIG. 6. This graphdemonstrates the relative torque on the y axis a similarly rated singlephase 8, three phase 9 and 17 phase electrical machine 10. The x axisindicates the motors angular position over a range of 0 to 360 degrees.Because the 17 phase electrical machine configuration effectively hasmore phases than the other electrical machine configurations it has amore constant producible torque and a much smoother torque without anysmart software control or otherwise controlling the electrical machine.In certain applications the achievable torque may be even smoother withthe aid of software algorithms and feedback control. Although the peakinstantaneous torque producible of the other motor configurations islarger than that of the 17 phase electrical machine, the power beingdelivered is approximately the same, the power from the other motortypes is applied largely in short bursts making it harder to control.

One of the features of certain disclosed embodiments is that there maybe an offset between a coil and a pair of magnets, i.e.: if there is ncoils and n+1 magnets, then the magnets may not perfectly align with thecoils. This ensures that the electrical machine of these embodimentswill be able to turn on at least one coil to turn the machine, whilealso having the effect of smoothing the torque applied to the machine.Because there is an offset between coils and magnets, it has the effectof making the motor into an n phase motor. In a traditional electricmotor, when less power is required, the amount of power applied in eachrotation to the motor is reduced. This reduces the produced torquenon-linearly. In certain disclosed embodiments as one or more coils (oreach coil) are able to be digitally controlled, coils that produce lessoptimal instantaneous torque onto their corresponding magnet may beturned off. This causes a non-linear reduction in torque with respect toreduction in power.

FIG. 7 illustrates the non-linear increase in heat generated due toresistive losses as power is increased in different electrical machineswith different number of phases, with comparative power between theelectrical machines. Certain embodiments of a 17 phase machine 11 arecompared to a three phase 12 machines with substantially identical inputpower. The x axis is a comparative axis of the percentage of power andthe y axis is the power loss through resistive heating. Thisdemonstrates the superior power handling capability of the certainembodiments disclosed herein, if the power to the coils is linearlyadjusted from 0 to 100% which is possible due to direct microprocessorcontrol. Having more phases for power divides the current suppliedbetween each of the phases substantially equally and as such the powerloss due to resistive heating is non-linearly reduced by the factor ofthe number of phases, as power loss is typically equal to the currentsquared times the resistance of its conductor. This means that todeliver the same power as other motor types certain embodiments may bemuch smaller and/or lighter than existing motor types and/or be capableof handling higher power requirements and outputs.

Torque Smoothing vs. Operating Frequency

Because torque applied at any instantaneous moment is a function of theangle of the motor platter, the apparent torque smoothing will vary withfrequency, i.e.: as the motor speeds up, the variations in torque willbecome less obvious. Since certain embodiments may be operated with nphases, one or more coils (or each coil) may operate n times faster thanit would on a single phase motor. The torque may be further smoothed byusing digital algorithms to limit the maximum power applied to a coil inthe optimal position. This may have the effect of slightly reducing themaximum torque, but would substantial smooth the torque output. FIG. 6shows a graph that demonstrates the superior torque smoothing of certaindigital axial flux motor embodiment compared to some standard motortypes. One of the advantages of the motors in these embodiments is thatit can individually control power to each coil (or one or more coils),allowing it to maintain suitably high output powers and/or torques whilekeeping its n phase torque smoothing characteristics. These embodimentshave the ability to change on the fly, for lower rpm's where torquesmoothing is more important, the motor may intelligently apply asmoothing profile, or a profile for suitable maximum torque and/oroutput power as it is required, or at higher rpm's.

Rotor

Exemplary embodiments of the present disclosure may consist of one ormore rotors. One of their purposes is to create a magnetic field in thevicinity of the electromagnets, such that the stator coils induce torquein the rotor. Magnets may be secured within the rotor via multiplemethods. For example by gluing; clamping (between two or more rotorlayers) and/or interference fit (with the surrounding hole);mechanically fixing (for example, bolted, threaded or other suitableways); welding (when applicable to chosen magnet and/or rotor material);sintering; other effective means or combinations thereof.

The rotor may be constructed from a number of materials. Constructionmaterials chosen for the rotor may vary depending on the application ofthe motor, as well as the chosen magnetic field strength between therotors. In certain embodiments, the chosen material will typically be ofsufficient Young's Modulus (stiffness) to prevent unacceptabledeformation or substantial deformation due to the axial magnetic forcesbetween two separate rotor platters. Materials used may include (but arenot limited to): aluminium; polymers, such as HDPE (High densitypolyethylene); fibre reinforced polymers, such as carbon fibre orfibreglass; other suitable materials or combinations thereof.

Magnetic Rotors: In certain embodiments, the need for separate magnets(which are then attached to the rotors) may be eliminated (or reduced)through the use of sintering to bond separate magnets and the mechanicalcasing into substantially one structure. A finishing surface may then beapplied (for example, nickel, epoxy) to increase mechanical strengthand/or durability.

Reluctance configuration: In certain embodiments, it is possible for themagnets to be replaced in whole or in part with a ferrous annular ringor disk and/or with a series of partial depth radial slots creating aseries of protruding fins. When a fin is within the vicinity of themagnetic field of the stator that fin may rotate and align itself withthat field, resulting in a reluctance motor configuration. Inductanceconfiguration: In certain embodiments, by replacing one or more, asubstantial portion of, or all of the magnets in the rotors with coils,the stator coils magnetic fields will induce magnetic fields in therotor coils. In certain embodiments by wiring the rotor coils to theirsymmetric or offset equivalent coils (with respect to the rotor),opposing magnetic fields may be induced, resulting in rotational forces.Material Reduction: for certain applications it may be advantageous toreduce the rotational inertia of the rotor and/or shaft assembly. Tothis end the rotor discs may have their shape changed to remove excessmaterial which is not necessary to the mechanical structure of the disk.

Shaft and Spacers: In certain embodiments, the rotor assembly may belocated within or partial within the motor enclosure through the use ofa shaft. This shaft may have a non-uniform diameter such thattranslational movement of the rotor magnet platters in the rotationalaxis of the shaft is reduced, substantially prevented or prevented. Thetranslational forces may be absorbed from the shaft into the casing.Methods include (but not limited to): axial thrust bearings or otherball, pin or conical bearings; interference between shaft and assemblywith low friction surface; the shaft may be of sufficient diameterand/or stiffness such that bending due to magnetic forces between rotorplatters does not occur or is sufficiently reduced. In certainembodiments, the materials that may be used for shafts and/or spacersinclude metals (such as steel, aluminum), polymers or other suitablematerials. Torque transmission: In certain embodiments, once torque isinduced in the rotor it may be transmitted either mechanically throughdirect fixture to a shaft, via magnetic couple to an external magneticplatter, mechanical coupling to a shaft (egg. via a clutch), othersuitable means or combinations thereof. In certain embodiments, it ispossible for the shaft to be removed entirely (or partially) andreplaced with a spacer, or multiple spacers, to separate two or morerotor platters. In these configurations the assembly may be locatedwithin the enclosure through the use of magnetic suspension.Alternatively, in certain embodiments, an annular bearing supporting theinner or outer radial edge of the rotors (or a substantially portion ofthe rotors) may be used. These configurations may or may not use acentre spacer to separate rotors axially, depending on the number ofbearings used.

Magnets

Certain embodiments of the electrical machine disclosed herein mayincorporate different types and/or shapes of magnets. One of thepurposes of the magnets is to induce a magnetic field, through whichsuspended electromagnetic coils can pass (thus inducing kinetic forceson the coils/rotors). Applicable types of magnets include, for example:rare earth magnets including but not limited to Neodymium,Neodymium-boron, Samarium-cobalt alloys or combinations thereof; varioustypes of superconducting magnets; standard and/or permanent magnets madeof materials such as but not limited to Alnico, Bismano, Cunife, Ferico,Heusler, Metglas, and other magnetic alloys or combinations thereof;electromagnets, such as wire coils, that may induce an electromagneticfield; magnetic fields resulting from materials with encoded quantumspin effects; induction magnets, in which ferrous material exposed to aperpendicular, or substantially perpendicular, electromagnetic field maybe subject to a force pulling it towards the center of theelectromagnetic field; other suitable magnets; or combinations thereof.

In certain embodiments, magnet shapes that could be used but not limitedto are: cylinders; cuboids (suitable 3D shapes); segmented, where themagnet is made up of in whole or in part a cluster of smaller magnets;Trapezoidal; solid or hollow (e.g. toroidal shape or hollow cylinder);Groups, either of the substantial the same polarity or opposing; angularand/or radially offset repetition of above arrangements; other suitableshapes for a particular application; or combinations thereof. Thethickness of magnets may be either equal to or not be equal to thestator mount/platter thickness. The thickness of coils may be variableto suit the application. In certain embodiments, the number of magnetsand coils may or may not be set such that: the number of coils never isthe same as the number of magnets, to ensure one or more, asubstantially plurality or all the magnets and coils never completelyalign; if number of coils is equal to number of magnets, the magnet orcoil position is geometrically offset to substantially prevent, prevent,or reduce their concentric alignment or combinations thereof. In certainembodiments, the magnets and/or coils may be aligned such that: magnetsmay suitably axially aligned with coils or vice-versa, such as in anaxial flux configuration; magnets are suitably axially misaligned withcoils or vice-versa up to 20, 25, 30, 35, 40, 45, 50, 55, 60, or 65degrees; aligned, or substantially aligned, with the platter;substantially perpendicular, or perpendicular, to platter; othersuitable configurations perpendicular or combinations thereof.

Stator

Certain embodiments of the disclosed electrical machines may incorporateone or more stators which may be used to locate the electric coils. Thestator may be incorporated directly into the casing, independent or acombination thereof. As such the materials chosen for the stator followthe same convention outlined in the ‘Material’ section of the casingdescription or disclosed elsewhere herein. The chosen material may behighly (or suitably) conductive both electrically and/or thermally. Incertain embodiments, the one or more stators may be used as electricalconductor (power delivery), as heat sinks (from the electronics andcoils to casing), as well as mechanically supporting the coils andelectronics or combinations thereof. In certain embodiments, the one ormore stators may allow transmission of communication signals, eitherdigital or analog, superimposed on the power layer, on its own layer, orcombinations thereof. Thus, layers in the stator may be electricallyinsulated from each other, if they are used for electrical conductionpurposes. In certain embodiments, methods of insulation may include:oxide layers on metallic surfaces; using insulating materials betweenlayers such as plastics or other appropriate materials, or combinationsthereof. In certain embodiments, gaps may be included in the one or morestators to reduce material required and/or the weight. When the statoris constructed out of conductive material gaps may be added to eliminateeddy currents from forming around the coil. For example as shown in FIG.8 a gap 14 in the conductive stator 15 is introduced in the stator nearthe location of the mounting hole for the magnetic coil 16 breaking theconduction path of the eddy current 17 induced when a current flowsthrough the magnetic coil. In certain embodiments, the gaps are locatedsuch that two concentric annular rings are not formed radially on eitherside of the ring formed by the coils.

Coils

Certain embodiments of the disclosed electrical machines may incorporatedifferent types and/or shapes of inductive coils, the purpose of whichis to by use of electric current, induce and/or alter an existingelectromagnetic field, creating a force which causes the rotor of themotor to turn. In certain embodiments, the coils may be constructed ofsufficient materials to handle both the heat and the electric currentrequirements of the motor; the coils may be constructed so as to lowerthe electrical resistance to ensure there is minimal power loss due toresistive heating; the coil may be constructed such that they produce amagnetic field sufficiently large enough to create sufficient force orcombinations thereof. One exemplary coil is shown in FIG. 9.

In certain embodiments, coils may be constructed as an air core, theconductive material is wrapped or rolled in such a way that there is anair gap in the middle of the coil; solid core, there is no (or suitablylittle) air gap in the middle of the coil. In certain embodiments, thecore may either be made of the conductive material used or be anon-conductive material, either ferrous or nonferrous. Ferrous materialswith a high magnetic permeability increase the magnitude of the magneticfield for a given current before the magnetic material saturates. Incertain embodiments, the coil may be interleaved, the coil is made fromconductive ribbon and/or sheet. The ribbon is coiled from the centrecore to the outside while interleaving layers of insulated ferrousmaterials. The ferrous material acts as an insulator and as a corematerial to enhance magnetic field proportional to the number of loopsof the ribbon. The magnetic field may reach its maximum magnitude at thecentre of the coil with a sine distribution on either side. Combinationsof the various constructions disclosed herein are also contemplated. Thecoils may be constructed in one or more of the following shapes:round/cylindrical, square/cuboid, trapezoidal, solid or hollow (airgap)/annular, and other suitable shapes.

In certain embodiments, the electromagnetic coils may be wound, bentand/or otherwise constructed from one or more pieces of a conductingmaterial, or a sufficiently conducting material. The coils may be 3Dprinted or otherwise made. The conductor may be 3D printed along with acore (if 2 material (or more) 3D printing is used). The conductor may be3D printed and the core added in a separate process. 3D printing refersto selective laser sintering, selective electron beam melting and/orother selective deposition techniques.

In certain embodiments, coils may be affixed to the stator by: aglue/bonding agent, clamping, mechanically, welded, 3D printed directlywith the stator plate, or combinations thereof.

In certain embodiments, the conductor of the coil may be composed ofcopper, aluminum, carbon structures such as graphene or other suitableconductive material.

In certain embodiments, the ferrous material may be constructed out ofelectrical steel, amorphous metal or other high magnetic permeabilitymaterial.

Coil and/or Magnet Positions

In certain embodiments, coils and/or magnets may be arranged/varied inmany different physical configurations. In certain embodiments, an axialflux configuration may be used comprising: at least one, two or multiplerotor platters of magnets creating an alternating magnetic fieldparallel, or substantially parallel, to the axel; and a plurality ofcoils between magnetic fields.

FIGS. 10, 11 and 12 exemplify a number of different configurations ofthe electrical machine. FIG. 10 illustrates a cross section view of arotor platter configuration according to certain embodiments. Theplatter 18 has a differential carrier 19 and a plurality of alternatingpole orientation magnets 20 and 21 (in this exemplary embodiment 18magnets are present) and coils 22 (in this exemplary embodiment 23 coilsare present). The magnets are arranged in a substantial concentricconfiguration arrangement near the outer edge of the platter. FIG. 11 issimilar to FIG. 10, but has two rotor, element 8 which create a moreconcentrated magnetic field across the coils, 22. Also shown is a spacer63 between the two platters. FIG. 12 is similar to FIG. 10 in a triplerotor platter configuration. This configuration permits more power to beadded by adding appending extra coil platters.

FIG. 13 shows a top down view of the rotor platter 18 in theconfigurations illustrated in FIGS. 10 to 12. Shown are the 18alternating polarity cylindrical magnets 20 and 21, distributed radiallyon the rotor platter 18. Also shown is the location of the differentialcarrier 19.

Certain embodiments of the disclosed electrical machines may beconfigured in a substantially circular array (radially aligned) wherein:a plurality magnets and a plurality of coils may be axiallyperpendicular (or substantially perpendicular) to at least one rotorshaft's primary axis. In these embodiments, the magnetic properties of anormal axially aligned stator motor are present with the added benefitsof fine grained adaptive magnetic flux control. FIG. 14 shows aschematic top view of a rotor platter 23 wherein the magnets 24 and 25are axially perpendicular (or substantially perpendicular) to therotor's differential carrier 10 and are at least partially within theplatter, according to certain embodiments. Also shown are a plurality ofcoils 22 that are also axially perpendicular (or substantiallyperpendicular) to the rotor's differential carrier 10 and are configuredconcentrically around the outer radius of the platter embodiments. Thestator 26 can be seen holding coils 22 radially around the magnets. Aclearance gap 27 can be seen between the magnets and the coils. FIG. 15shows a perspective view of the configuration of FIG. 14.

Certain embodiments of the disclosed electrical machines may beconfigured in a substantially circular array (radially aligned) wherein:a plurality magnets and a plurality of coils may axially perpendicular(or substantially perpendicular) to at least one rotor shaft's primaryaxis. Such embodiments have the magnetic properties of a normal axiallyaligned stator motor, with the added benefits of fine grained adaptivemagnetic flux control.

End Caps

Magnetic fields that are not constrained may couple onto conductivesurfaces and induce eddy currents which may create magnetic fieldsopposing the motion of the magnets. For example, FIG. 16 is a sidecross-sectional magnetic field diagram of a linear array of evenlydistributed magnets, where consecutive magnets 20 have their north polefacing up, and the rest of the magnets 21 have their north pole facingdown, with electromagnetic coils in the middle inducing a magnetic fieldnorth 28 and south 29. FIG. 16 illustrates the external radiatingmagnetic field 30 without any shielding. FIG. 17 illustrates thereduction in radiated electromagnetic energy in the scenario describedin FIG. 16 with ferrous shielding plates 31 added. In certainembodiments, a Halbach array arrangement may be used instead of theferrous shielding. FIG. 18 illustrates the reduction in radiatedelectromagnetic energy in the application described in FIG. 16 with aHalbach array arrangement of magnets used on the top platter. TheHalbach array arrangement may use smaller magnets 32, and oppositepolarity magnets 33. The smaller magnet is positioned between the twolarger magnets with a magnetic field substantially perpendicular tothose of the bigger magnets. The smaller magnet bends the magnetic fieldlines from the first large magnet to the next large magnet and reducesthe distance to which the flux loops past the end of the plate 33. Thishas close to the same effect of adding a ferrous shield to the system,and may dramatically reduce the external electromagnetic energy; thishas the effect of saving the weight of the ferrous shielding plates thatwould otherwise be used in this application. Ferrous shielding 31 isused on the bottom layer of magnets for comparison.

Enclosure

The enclosures discussed herein serve numerous purposes. In certainembodiments, it may be designed to cover or enclose (partially,substantially or fully) the moving parts and circuit boards, it can alsohold one or more coils in place, the electronics in place, provides asource of heat sinking away from the coils and/or electronics, it cansupport the bearings and/or absorb axial forces on the shaft, it may beused as a conductor to shunt electrical power to and/or from theelectronics, or combinations thereof. The enclosure may be constructedfrom materials (or combinations of materials) which are sufficientlystrong to resist (or substantially resist) deformation due to loadsapplied from the half shafts. Additionally, in certain embodiments, itis desirable for the casing to sufficiently resist thermal fluctuationsresulting in part from the electronics current draw. Example materialsthat match these properties include, but are not limited to: aluminium,polymers or other suitable materials.

In certain embodiments, the enclosure may or may not be electricallyconductive. In certain embodiments, power and signal lines may routeplacements but the casing itself is not used as a conductor. In certainembodiments, the casing itself may be used as a conductor. In certainembodiments, portions of the enclosure may be electrically conductive,typically with conductive parts separated by insulating layers. Suchconfigurations allow power to be supplied directly (or indirectly) tothe electronics through the casing. In certain embodiments, conductivemount points may be attached directly (or indirectly) to the outsideand/or inside of the casing. In certain embodiments, portions of thecasing may be used as conductors, for example, signal transmission.Nonconductive sections may be used to isolate conductive sections toallow multiple signal ‘lines’ through the casing. In certainembodiments, power configuration and/or electronic communication and/orother signals may be multiplexed onto the power lines at a higherfrequency by means of a suitable technology such as Direct SequenceSpread Spectrum (DSSS). The present disclosure also contemplatedcombinations the enclosure configurations discussed herein. In certainembodiments, one or more circuit boards may be replaced withconductive/tracks/pads routed and/or etched directly into the devicecasing. In certain embodiments, at least a substantial portion of thecircuit boards may be replaced with conductive/tracks/parts routedand/or etched directly into the device casing.

In certain embodiments, one of the purposes of the casing may be toextract heat from the electronics (for example, the coils). It is usefulif this heat is transferred to the environment surrounding the casing asefficiently as possible. In certain embodiments, methods of cooling thatmay be implemented include one or more of the following: active cooling(forced air flow); active cooling (force liquid flow); active cooling(refrigeration); passive cooling (heat pipe/pump transfer); passivecooling (convective heat fins, ribs); passive cooling (convectionholes); active or passive cooling (convection channels); chambered(sealed static fluid with high thermal conductivity to concentrateand/or direct heat flow); and entire enclosure sealed withnon-electrically conductive fluid.

In certain embodiments, circuit boards (and their attached electronics)may be mounted such that they do not move when subject to external orinternal forces (linear or angular accelerations of the motor) orvibrations. In certain embodiments, circuit boards (and their attachedelectronics) may be mounted such that they do not substantially movewhen subject to external and/or internal forces (linear or angularaccelerations of the motor) or vibrations. In certain embodiments,circuit boards (and their attached electronics) may be mounted such thatthey are sufficiently stable when subject to external and/or internalforces (linear or angular accelerations of the motor) or vibrations. Incertain embodiments, circuit boards (and their attached electronics) maybe mounted using one or more of the following methods: specificallyshaped cavities in the casing such that circuit boards can slot in witha transition or interference fit; modular inserts; circuit boardssandwiched between two casing components; mechanically fastened orclipped; glued, or otherwise permanently joined.

For applications that are not as mechanically constrained thisrepresents a more flexible electrical and mechanical solution. Incertain embodiments, electronic components (and/or circuit boards) maybe attached to modular inserts that may be slot/snap/or be otherwiseattached to the primary casing externally, without the need todisassemble other inserts and/or the primary casing. In certainembodiments, electronic components (and/or circuit boards) may beconfigured as a modular insert that may be attached to the primarycasing externally, without the need to disassemble other inserts and/orthe primary casing.

In certain embodiments, the electrical machine may include one or moreof the following: at least one electrical bus, at least one optical bus,at least one radio frequency channel and a bus consisting of one or moredigital and/or analogue communication channels. For example, whenmultiple microcontrollers are used, inter communication betweenmicroprocessors typically may occur over a bus. This bus may be mountedand constructed in one or more of the following ways: for electricalconductor (groove cut for circuit board, or other form of conductor tomount); for optical conductor (cut directly into casing, with reflectivecoatings applied to cut surfaces, and/or inserted into groove incasing); other suitable methods for mounting the conductor. In certainembodiments, when an optical bus is in use, optical transceivers on oneor more microcontroller may be mounted to interface with the bus. Thusthe microcontroller positions may be tangentially arrayed around theoptical bus. In certain embodiments, where optical or radio frequencytransceivers are used, the bus may be the voids within the enclosure.

In certain embodiments, another function of the casing may be to protectone or more internal components from external damage. It may bedesirable that the seams of the casing be waterproof. It may also bedesirable that the casing be covered in, and/or made partially of,vibration/impact absorbing coating (e.g. elastomer polymers). In certainapplications, the casing may be an optional mounting point for masterpower cut-off switch.

In certain embodiments, one or more power and/or control signals maypass through the enclosure. In certain embodiments, at least asubstantial portion of the power and/or control signals may pass throughthe enclosure. Mounts can be provided for these connections using one ormore of the following: lugs/clips, bolts, rings/sockets/clamps, weldpoints, and other suitable ways for mounting. Also for external controland/or information mounts one or more of the following may be used:switch mounts, calibration mounts (variable, quasi fixed controls), andembedded displays (LCD, or other). For Microcontroller Bus Interfacesone or more of the following may be used: galvanically isolatedconnections (optical, radio, magnetic), USB, Serial, other digital andanalogue connections, and other suitable ways or structures. In certainembodiments, for mechanical outputs when applicable, the differentialcarrier may pass through the casing via one or more of the followingways: optionally, a bearing seal, variable diameters, unsealed passthrough hole (exposed inner assembly) and other ways of sealing shaftpassthrough point. In certain embodiments, the enclosure may also havemounting points for magnetic coupling platters.

Switch Architecture

In certain embodiments, one or more electronically controlled switchesmay be used to control the size and direction of the current through thecoils. These switches may be made up of discrete components (e.g.,transistors and/or other silicon switch technology) including one ormore of the following: IGBT's or other similar technology; FET's orother Channel/Field effect transistor based device (MOSFETS etc); BJT'sor other bi-polar transistor based device; ECP or other emitter coupledtransistor device; digital switches such as transistors; silicon carbidetransistors; diamond switches; Triacs; Diodes; SCRs; other suitableelectronically controlled switching technology; and electromechanicalrelays. In certain embodiments, the one or more switches may be used todrive the electromagnetic coils and may be implemented in different waysand may be comprised totally or partially from one or more of thefollowing configurations/devices: single switch; an H-bridge (fullbridge); a Half bridge; a Half bridge with a high and a low sideswitching; bilateral switch configurations, single phase voltage sourceinverter, half bridge voltage source inverter, AC chopper regulation andother various one, two, three phase and multiphase configurations.

The switches may be obtained without their plastic packaging andembedded directly into the one or more coils. Switches may be integratedinto the body of the one or more coils, either after or during theconstruction process of the one or more coils. In certain embodimentsreferencing FIG. 19 where the high side switches 35 and 36, thetransistors may be biased to the high side of the coils. When usingPositive Field Effect Transistor (PFET) or Positive Negative Positive(PNP) Bi Junction Transistors (BJTs), a negative voltage is applied inreference to their positive input and the control pin may turn on thegates. PNP BJTs and PFETs are generally more expensive than NegativePositive Negative (NPN) BJTs, Negative FETs and IGBTs. These deviceswould turn on if the voltage at their controlling terminal is greaterthan the voltage at their negative terminal by a few volts. In certainembodiments, to achieve this one or more of the following may be used: acharge pump; an isolated DC-DC converter; a separate power supply; andother voltage boost methods may be used. It is possible to vary thecurrent flowing through the coil by use of pulse width modulation. Incertain embodiments, the switches may be turned on and off at a highfrequency, and by controlling the duty cycle (the time the switch is oncompared to the time the switch is off) the amount of current flowingthrough the coil is controlled by this duty cycle. If the switches arejust on (100% duty cycle), then the maximum current flows through thecoil. If the switches are off (0% duty cycle), then no current will flowthrough the coil. If the switches are on half the time and off half thetime the current could be 50% of the full current but may depend if theinductance of the coil at the switching frequency is too high or toolow. In certain embodiments, when the direction of current through thecoil does not need to be reversed, a single switch can be used betweenthe voltage source, the coil and the ground. This reduced the componentcount by three switches. In a single phase AC configuration the voltagecan be half rectified to create a positive rail and a negative rail. Thetwo rails can then be switched through the coil to ground effectivelychanging the direction of the current. This reduces the number ofswitches required by two. In certain three phase star configurations,the phase with the nearest ideal voltage may be switched so that powercan flow from that phase to ground. In certain delta three phaseconfigurations, two switches may be required on either end of the coilto each phase, in this configuration current can be selected to flowfrom one or more phases to one or more other phases.

Control

In certain embodiments, one or more control mechanics may be used withrespect to the driving operation of one or more electronic components.The one or more control mechanics may be implemented either at ahardware or software level, or both. In certain embodiments, the numberof coils activated at a particular instance may be varied from 0 to thetotal number of coils. The choice of this number may be based at leastin part upon the currently active control scheme. This decision may bemade at the Main Control Unit (MCU), Coil Control Unit (CCU) and/or anexternal level. In certain embodiments, motors may be configured tooperate in the clockwise, counter clockwise, or both directions. Incertain embodiments, in order to produce motion, coils may be switchedon and off at specific instants. These instances may be determined byone or more of the following:

A. Stored sequences including: observed (obtained via sensor feedback);streamed (obtained via external devices); precomputed (stored within themotor electronics);

B. Computed sequences including: sequential based activation (coils aretoggled sequentially in a rotary fashion with alternating polarity);Optimal force activation (coils are activated when their individualfeedback data indicates an optimal force will be applied to the rotor);optimal efficiency activation (coils are activated in a manner tomaintain target operating motor dynamics whilst minimizing powerconsumption); and random based activation (coils are activatedrandomly); pattern based sequence (coils are sequenced in apredetermined pattern); feedback frequency based (Coils are activatedbased on a driving analogue frequency signal); and

C. Other suitable driving sequence which achieves desirable motorperformance.

In certain embodiments, feedback may be used to generate and/or chooseoptimal driver routines/patterns to adapt the device to changingconditions such as but not limited to: changing temperature or othertemporary forces/stress' that may alter motor operational performance; adepleted battery/changing voltage supply; an increase in demand on agenerator or for mechanical output in an application; change inparameters of the device caused by damage and/or general wear and tear;or combinations thereof.

In certain embodiments, certain electrical machine parameters may becalibrated using sensor feedback or other ways of tuning. For example,the use of machine learning techniques, and/or other automated tuning,operating internally, externally or combinations thereof may be used.

In certain embodiments, the active control scheme can utilize severaltechniques to reduce power consumption and/or better optimize powerconsumptions. For example, one or more of the following may be used:dynamic reduction of active coil count (lower power per torque); dynamicreduction of active coil power percentage (smoother torque); back EMFreproduction/elimination optimization; and pulse width modulation of thecoil driving signal to allow precision control on power applied tocoils.

In certain embodiments, feedback monitoring may be used to detect faultsand automatically power off faulting devices. For example, one or moreof the following: coil current overflow protection/detection;over-voltage/Over power protection; overheating protection; and velocityoverspin protection. In certain embodiments, arbitrated mastermechanisms may be used such as master controllers may be nonsingular,with the resulting control signal arbitrated using a 3 way votingmechanism to ensure redundancy of the master controller. In certainembodiments, an external signal may be applied to bypass one or moresingle controllers with the purpose of shutting down, restarting, orreconfiguring the one or more controllers.

Feedback

In certain embodiments, feedback may be useful for optimal operationunder one or more conditions, but may be only cost effective forincorporation into certain devices. When feedback is not required, astandard open loop control may be used. Feedback may be utilized by thecontrollers, either by CCUs or MCUs or both. In certain embodiments,feedback may be collected local to each device or remotely and used ineither hardware and/or software as outlined in the control sections. Incertain embodiments, feedback may be collected local to one or moredevices or remotely and used in either hardware and/or software asdiscussed herein. In certain embodiments, feedback may be measuredand/or obtained in one or more of the following ways: instantaneousvoltage across a coil via an ADC, or otherwise, at any time orsubstantially any time; current through a coil or power supply, byeither contactless (hall effect) or contact current measurement; backEMF measurement, may be done while coil is not in a powered state;angular position, obtained by a sensor as discussed herein; magneticfield strength or angle; temperature; and vibrations via accelerometersor otherwise. In certain embodiments, angular positions of the rotor maybe obtained by measuring one or more of the following: absolute angle orposition; relative angle or position; and velocity. In certainembodiments, readings may be achieved through the use of sensors such asone or more of the following: Hall effect and/or other magnetic sensetechnology, such as GMR, AMR; rotary and/or quadrature encoder, opticalor otherwise; position/velocity detection sensors such as laser/opticaltrackers currently used in computer mice; and cameras in combinationwith software processing.

Controller Architecture

In certain embodiments, axial flux electrical machines may comprise:coil driving controllers, coil control units (CCU's) and/or motorcontrol units (MCU's). In certain embodiments, the layout of thecontrollers may be varied, while maintaining control of each coilindividually.). In certain embodiments, the layout of the controllersmay be varied, while maintaining control of one or more coilsindividually. In certain embodiments, the layout of the controllers maybe varied, while maintaining control of at least a substantial number ofthe coils individually. In certain embodiments, the layout of thecontrollers may be varied, while maintaining control of at least 50%,60%, 70%, 80%, 90%, 95%, 98%, 99% or 100% individually. The controllersdrive ‘switches’ as described in this disclosure, allowing control ofthe coils, as described in this disclosure. FIG. 20 illustrates oneexemplary relationship between an exemplary Motor Control Unit (MCU) 37,Coil Control Unit (CCU) 38 the communications buses 39, 40 that areavailable to them. One or more MCU's may be communicating with one ofmore CCU's. Also illustrated is the coil driver architecture, accordingto certain embodiments, which includes a one or more coil drivers 41 forone or more coils 22. The signalling between CCU's, MCU's 47 and coildrivers 42 may be galvanically isolated. FIG. 21 illustrates a CCUarchitecture, according to certain embodiments.

A Microcontroller 43 may be used to control the device; it incorporatesan Analogue to digital converter (ADC) with an external interface 44 forcollecting data from sensors 45. A Communications transceiver 46 isconnected to the microcontrollers serial bus 47 allowing it to receivecommands and exchange data with a MCU. The microcontroller controls acoil driver 41 by use of a digital bus and/or PWM signals. The coildriver takes a high voltage input 48 and controls the supply of that tothe coil 22. The microcontroller and other peripheral low power devicesmay be supplied by a high efficiency DC to DC converter 49. Galvanicisolation is optional at several points 42. In certain embodiments, thenumber of controllers used may be varied depending on specific needs ofthe application. FIG. 22 shows a 1:1:1 configuration such that oneindividual Motor Control Unit (MCU) 37 communicates with one CoilControl Units (CCU) 38, which in turn controls for each switch and orswitch driver 41 in a 1:1:1 configuration. (for example as shown in FIG.22); many switches controlled by one or more CCU's, in a 1:n (forexample as shown in FIG. 23) or m:n configuration (for example as shownin FIGS. 24 and 25); motor Control Unit (MCU) may control CCU's, givingvelocity and/or other commands; and MCU's may directly control one ormore coils, bypassing the need for CCU's.

In certain embodiments, the controllers may be implemented throughmultiple ways, examples include one or more of the following:utilization of software and/or hardware features in an embedded systemsuch as a microcontroller or microprocessor; the use of an FPGA, CPLD,ASIC or other VLSI or programmable logic device; an analog system, suchas the use of classical electrical feedback topologies to create basiccontrol loops; and combinations thereof.

FIG. 26 illustrates a certain embodiment, in which there is multiplemicroprocessor configurations, the master controlling processor may be,for example, a CCU 38. In certain embodiments, CCU's may actindependently, without the need for a master controller. In certainembodiments, CCU's may act independently, without the need for a mastercontroller wherein synchronous behavior may be achieved through the useof common sensors, or sensors with predictable and consistent readingsrelated to the electrical machines behavior. In certain embodiments,where the motors speed and/or power is uniform (or substantiallyuniform), and the only input to the system is that the power is on oroff, a common communication bus may not be required.

Certain embodiments are directed to an MCU's (Motor control unit) in astandard master slave configuration where a single motor control unit isconnected to a common communication bus, which is connected to one ormore coil control units. Certain embodiments are directed to an MCU's(Motor control unit) in a standard master slave configuration where asingle motor control unit is connected to a common communication bus,which is connected to at least 70%, 80%, 90%, 95%, 98%, 99% or 100% ofthe coil control units. FIG. 27 shows a configuration where a singlemotor control unit (MCU) 37 is connected to a common communication bus47, which is connected to each of the coil control units (CCU) 38.Certain embodiments are directed to redundant master slave configurationwhere multiple masters arbitrate to come to an accepted value. Forexample 2, 3, 4, 5, 6, 7, 8, 9, or 10 MCU's may calculate commands tothe CCU's, but only one MCU's commands are used by means of anarbitration method. In this way in the event of failure the failed MCUwill be ‘outvoted’ and their commands discarded, possibly even beingpowered off by the other MCU's. Other embodiments may include redundantMCU's in case of failure, which only actively send commands when anotherMCU has failed. FIG. 28 shows a configuration where 3 motor controlunits (MCU) 37 are connected to a common communication bus 47, which isconnected to each of the coil control units (CCU) 38. In certainembodiments, it is possible to have configurations wherein one or moreof the coil control units are not in communication with the plurality ofmotor control units. In certain embodiment, one or more of the CCU's mayact together as a group, sharing sensor data and/or providing commonoutput. In such embodiments, communication may occur via a common bus ordirect peer to peer. In such embodiments, a motor control unit may notbe required. FIG. 29 illustrates a configuration wherein no centralcommunication bus is present and communication from each CCU 38 is pointto point 50. FIG. 30 illustrates a configuration wherein a centralcommunication bus (token ring) 51 is used for communication between CCUs38. In both FIGS. 29 and 30 a MCU is not required.

In certain embodiments, power systems for supplying the digital logicand/or other devices in the CCU's and/or the MCU's may need to convert ahigher or lower voltage to the operating voltage of the devices used,and can take one or more of the following the topologies: DC-DCconverters, switching such as buck or boost; linear regulation orotherwise; transformers; resistive supply (by division); and opticalpower transfer. In certain embodiments, power may be supplied to thecontrol units, CCU's, MCU's, an overall motor and/or another device.Such implementations may include one or more of the following: using thesame (or substantially the same) supply the switches use, such as whenswitches are mounted to a motor casing; from RF/EM ‘waste’ or‘background’ energy harvesting; via EM induction/generation, such as inthe application of a generator; batteries, either per CCU/MCU deviceand/or otherwise, rechargeable or non-rechargeable; solar, wind, hydro,fuel cell and/or other forms of renewable energy sources; and mainssupply, single phase, three phase at a variety of different voltages.

In certain embodiments, power supplies for switches and/or CCU's/MMU'smay also have power control overrides, as a safety feature, allowingpower to be turned off to one or more CCUs or coils. This can beimplemented via suitable switching topology, for example, as discussedherein.

In certain embodiments, communications between a MMU and an externalcontroller, MMU and internal CCU and/or other devices may begalvanically isolated by using one or more of the following methods:optical (IR or other spectrums) over a physical medium as a light guidelike fiber or shaped plastic, through space/air or otherwise; radioFrequency of suitable spectrums, physical layer technology, and/orencoding method, such as Direct Sequence Spread Spectrum (DSSS), O-QPSKor otherwise; conductive, via wires and/or other electrically conductivematerial, and isolated via the use of a galvanically isolatingtechnology such as: RF isolation IC's, transformers, capacitive, opticalisolation IC's, or combinations thereof.

FIG. 31 illustrates a configuration with three redundant communicationbuses 52. In certain embodiments, the communication layers may have 2,3, 4, 5, 6, 7, 8, 9, 10 or more redundant layers.

In certain embodiments, communications inside the devices betweencontrollers/drivers/MCU's 37 and/or CCU's 38 and/or to external devices,(e.g. vehicle control unit to MCU) may involve one or more of thefollowing technologies and/or communications protocols in combinationwith one or more of the physical layer implementations disclosed herein:single ended, serial and/or parallel (for example UART, SPI, or I2C),differential signalling, (for example CAN bus or RS485 protocols),optical point to point and/or optical bus and RF communications.

With reference to FIG. 32, FIG. 33 and FIG. 42, two embodiments areillustrated of a brushless, axial flux, direct-current electric motorwith integrated differential 53 comprises one or more disc-shapedstators 54. The stator may be constructed out of a non conductivematerial, for example, nylon 12, fibreglass composite, Kevlar composite,other suitable materials, or combinations thereof may also be used toprevent (substantially prevent, sufficiently prevent or reduce) thegeneration of an electrical eddy current around one of more of theelectromagnetic coils. An alternative embodiment is (illustrated in FIG.8) may be constructed from a conductive material such as aluminium withslots 14 extending more or less radially inwards from each apertureaccommodating a the electromagnetic coil. In certain embodiments, theelements may be made from a light material of suitable mechanicalstrength and/or conductivity, such as an aluminium or magnesium alloy,and the external surfaces may be finned or ribbed to provide greaterheat dissipation surface area. Alternatively in certain embodiments thering may have a cavity or other suitable passage for coolant in oraround the stator and/or in close proximity to the stator. In certainembodiments, the ring may accommodate the distribution of coolantdirectly onto the coils and/or cores. Other suitable heat dissipationmechanisms or methods may be used.

Around the periphery of the stators is embedded a circular array ofequally-spaced, or substantially equally-spaced, electromagnetic coils22, heat from the coils may be conducted out to the exterior surface ofthe annular conductive elements by means of a channel inside the coil.Conductive elements 55 connect to Coil Control Units 38. The CoilControl Units consist of one or more stacked circuit boards 56. Thesestacked circuit boards may be parallel, substantially parallel and/orother suitable configurations. In certain embodiments, (not shown), thecircuit boards may be partially, or wholly, replaced by a system ofinternal conductors. In certain embodiments, the circuit boards may besupported by the solder tags of solid-state switches 57 being solderedto them, the switches, in turn, being fixed (as described elsewhereherein) to a heat sink elements 58. In certain embodiments, (not shown)the circuit boards are supported from the stators by a suitablestructure, including conductive brackets, insulating brackets, pillars,struts or combinations thereof. On the PCB there can be four solid stateswitches such as IGBTs in a H-Bridge configuration. The IGBTs, incertain embodiments, may be connected to a heat sink with anelectrically insulating, thermally conductive layer such as Mica,aluminium oxide, aluminium nitride or other suitable insulation toisolate the various voltages (not shown) which then slides into acooling ring. The heat sink 58 can be retained in the cooling ring byscrews or a springs or cam locks (not shown.) The cooling ring containsone or more cooling channels 74; the coolant enters the cooling ringthrough an inlet and exists through an outlet. A set of connectors madeout of a conductive material such as copper that permits the connector59 to connect to the power rails. The power rails comprising of a firstannular conductive element 60 and second annular conductive element 61,the conductive elements may be separated by an electrically insulatinglayer 62. In certain embodiments, the insulating layer may be made froma mechanically tough material having a high dielectric value, such asAcetal. Other suitable materials may also be used. In certainembodiments, (not shown) the stators may be electrically separated byhard anodising of their surfaces with care taken to ensure that theanodising extends substantially, or sufficiently, to their edges, theanodising being employed alternatively and/or in addition to theinsulating layer.

During assembly and/or maintenance a single Coil Control Unit can beremoved by detaching the conductors from the coils, disengaging theretaining mechanisms and sliding the Coil Control Unit in or out therebyremoving or installing the CCU from the device, two examples aredepicted in FIGS. 34 and 43.

With reference to FIG. 32, FIG. 33 and FIG. 42 again, the electric motormay further comprise one or more disc-shaped rotors 18 around theperiphery of which may be embedded in a circular array of equally-spaced(or substantially equally-spaced), powerful permanent magnets 20, thearray may have the same, or substantially the same, centre diameter asthat of the electromagnetic coils and the magnets may have alternatingpole orientation. In certain embodiments, (not shown), the centrediameters of the arrays of permanent magnets and electromagnetic coilsmay be made unequal but such that the magnetic fields of the magnets andcoils intersect. In certain embodiments (not shown), the poles of thepermanent magnets in the array may have like orientation. In certainembodiments, (not shown), the permanent magnets in the array may be madein groups, the polar orientation of the magnets being common in eachgroup while the polar orientation of adjacent groups may be opposed. Incertain embodiments, (not shown), the permanent magnets in the array maybe made in groups, the polar orientation of the magnets being common inone or more of the groups while the polar orientation of adjacent groupsmay be opposed. In certain embodiments, (not shown), the permanentmagnets may be arranged in groups of unequal numbers, the polarorientation of the magnets in a group being common. In certainembodiments, (not shown), the permanent magnets pass through the wholeof the axial depth of the rotors and may be orientated parallel, orsubstantially parallel, to the rotational axis, but with their centredistances randomly displaced (displaced inwardly or outwardly in aradial sense) up to half their radial depth. In certain embodiments, thedisplaced (displaced inwardly or outwardly in a radial sense) may be upto 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 of their radial depth.In certain embodiments, (not shown), the permanent magnets in an arraypass through the whole of the axial depth of the rotor and may bedisplaced in common from being parallel (or substantially parallel) withthe rotational axis by a deflection in various senses of between zeroand 30 degrees. In certain embodiments, the deflection in various sensesof may be between zero and 30 degrees, zero to 20 degrees, zero to 40degrees, 5 to 40 degrees, 5 to 30 degrees, 5 to 10 degrees, 10 to 30degrees, 20 to 35 degrees or other suitable ranges. In certainembodiments, (not shown), the permanent magnets in an array pass onlypartly through the axial depth of a rotor, their inner ends optionallyabutting a back iron of suitable magnetically permeable materialembedded in the rotor. In certain embodiments, (not shown), thepermanent magnets and the electromagnetic coils may be arranged inpossible combination of the embodiments disclosed herein.

The rotors are bolted 75, splined or otherwise fixed to a differentialcarrier 19 parallel (or substantially parallel) to the stators with anair gap between the electromagnetic coils and the permanent magnets,suitable spacers 63 being positioned on the differential carrier tomaintain (or partially maintain) the rotors in correct (or suitable)axial separation. In certain embodiments, the differential carrier iscoupled to three or more bevelled gears. Two of the bevelled gears 64,65, that are axially aligned with the rotor are splined to accommodatecomplementary splining of two half shafts. The remaining bevelled gears66 are mounted perpendicular, or near perpendicular, to the axiallyaligned gears transfer the rotational energy to or from the rotors totwo or more shafts, while permitting the two shafts to rotate atdifferent angular velocities. The outer ends of the differential carrieris rotationally supported in suitable bearing 67 carried in the bearingsupport 68 or the casing 69 of the electric motor. The position of thebearing can be adjusted through the use of a screw collar 70 or by theuse of spacers to ensure correct alignment. The casing may comprise of aclamshell or a radial enclosure 71, 72. The enclosure is sealinglyclosed by a bearing housing 68 which accommodates suitable thrust ordeep groove bearing 67 and a suitable sealant (or sealing means) (notshown) which rotationally support the differential carrier,substantially prevent or sufficiently prevent the egress of lubricant orthe ingress of contaminants. To provide a flux return path, annular backirons 31 of a suitable magnetically permeable material may be providedon one or more faces (or each face) of a the rotor not facing a thestator, the back irons covering the annular zone occupied by themagnets. In alternative embodiments (not shown) in the rotors having aface not immediately adjacent the stator, the back irons may be deletedand the magnets take the form of suitable Halbach arrays. Electronicshousing 73 is formed on or fixed to a suitably located part of thehousing and contains control circuit board 37. The solid-state switchesare activated by command signals from a control system (not shown) topower the electromagnetic coils and thereby cause the rotors to rotate.Suitable sensors (not shown) are provided to generate signals that aretransmitted to the control system to provide data as to the absolute andinstantaneous positions of the rotors. In certain embodiments, one ormore suitable sensors (not shown) may be provided to generate signalsthat may be transmitted to the control system to provide data as to theabsolute, substantially absolute, or sufficiently absolute and/orinstantaneous, substantially instantaneous, suitably instantaneous,relative, or substantially relative positions of one or more of therotors, or any combination thereof. In certain embodiments, the sensorstake the form of one or more optical sensors and/or one or moreHall-effect sensors. In certain embodiments, (not shown), rotor positionmay be determined by reference to the back EMF generated in undrivencoils. In certain embodiments, the permanent magnets may take the formof powerful, or sufficiently powerful, rare earth-type magnets and maybe secure in position within the axial depth of the rotors by, forexample, bonding, by suitable mechanical fastenings or, as depicted inthe Figure in the central the rotor, by imprisonment between two partsclamped together. In certain embodiments, (not shown) which may beemployed in lower cost applications and/or those required to meetdifferent operational parameters, the magnets take a conventional form.The body parts of the rotors are made sufficiently strong and/or rigidto suitably resist magnetic forces generated during operation and/orwhen the rotors are at rest: The rotor body parts are optionally madesolid and/or partially hollow with radial ribbing 76 to reduce rotatingmass and/or confer stiffness.

In certain embodiments, the electromagnetic coils can be made in theform described in relation to FIG. 9 and generate suitably highermagnetic flux levels while having suitably lower magnetic reluctancepermitting rapid switching and/or reversal of magnetic polarity. Incertain embodiments, (not shown), coils of conventional, wire-wound orribbon-wound, bobbin construction may be employed, with an air coreand/or core made from a suitable magnetically permeable material. Incertain aspects, the coil configuration may necessarily be a compromisebetween maximisation of current flow and minimisation of inductanceeffects and/or losses due to at least in part hysteresis. Electricalcurrent may be supplied to the solid-state switches via the annularconductive elements 60 and 61, thereby permitting a heavy current flowto the solid-state switches. A plurality of suitable lugs (depicted as78 in FIGS. 33 and 42) may be provided around the peripheries of theannular conductive elements for the attachment of electrical conductors.A high power fuse may be attached at this point to protect the machinefrom short circuits. The electromagnetic coils may be embedded withinthe axial depth of the stators and may be bonded into place and/orpotted with, for example, a high-strength, high-temperature epoxy resin,the arrangement permitting efficient (or suitably efficient) conductivecooling. The stators may be made sufficiently strong and/or rigid toresist magnetic forces generated during operation and/or when the rotorsare at rest. In certain applications, where the electric motor may beemployed as a direct-drive automotive wheel motor, it may be mounted tothe existing mounting points of a differential of a vehicle by suitablefastenings engaging attachment bolt apertures 77.

In certain applications, where the electric motor may be employed as adirect-drive automotive wheel motor, the centre diameters of the arraysof permanent magnets and arrays of electromagnetic coils fall in therange 15 to 60 centimetres, the number of the coils being odd and thenumber of the magnets being one more than the number of coils. Othersuitable ranges may also be used. In certain embodiments, 24 magnets maybe employed. In certain embodiments, 48 magnets may be employed. Incertain other embodiments employing similar operating principles, thenumbers of the permanent magnets and the electromagnetic coils mayoptionally be doubled, tripled or quadrupled and the coils powered asrequired to generate a desired torque and RPM. In certain applications,the number of the permanent magnets and the number of electromagneticcoils may 1, 2, 3, 4, 5, 6, 8, 10, 12, 14, 20 or more and the coilspowered as required to generate a desired torque and RPM. Similarly, inother alternative embodiments, the permanent magnets and theelectromagnetic coils may optionally be made in equal numbers.Similarly, in other alternative embodiments, the permanent magnets andthe electromagnetic coils may optionally be made in equal numbers, butwith locational asymmetry to prevent magnetic stasis at start-up. Incertain applications, the greater centre diameter of the arrays ofpermanent magnets and electromagnetic coils, the greater the torque ableto be generated. The arrangement of the electric motor permits manycombinations to be created from specially designed components, standardcomponents, or combinations thereof—from a single rotor and statorcombination to combinations employing at least 10 rotors. In certainapplications the number of rotors may be at least 5, 10, 15, 20 or 25.The combinations employing larger numbers of rotors and stators may beused in large devices or machines, such as heavy trucks and earthmovingequipment.

In certain embodiments, the solid state switches employed to provideelectronic commutation may be insulated-gate bipolar transistors (IGBT)which may be capable of handling the supply voltages required by theelectric motor. Although both p-type (P-FET) and n-type (N-FET)field-effect transistors may be suitable for the application, in thecertain embodiments, IGBTs may be employed in an H-bridge arrangementwith powering of the high side of each (or one or more) of the IGBT byan integrated circuit incorporating a charge pump. In the certainembodiments, IGBTs may be employed in an H-bridge arrangement withpowering of the high side of one or more of the IGBT by, for example, anintegrated circuit incorporating a charge pump. The positioning of theIGBTs within close proximity to the electromagnetic coils may provideshort, efficient conduction paths of low resistance. Other positioningmay also be used such as substantially adjacent, suitably adjacent or incommunication with. The type of the IGBTs employed may provide largetabs intended as heat sinks, but which may be also electricallyconductive. The tabs may be therefore fixed directly, or indirectly, tothe fingers of annular conductive elements 4, thereby providing theIGBTs with an efficient electrical current supply path with lowresistance, making efficient use of space and/or providing an efficientthermal conduction path out to the finned or ribbed exterior surfaces ofthe annular conductive elements.

DC to DC isolated converters and high voltage step-down regulatorcircuit boards may be mounted to the circuit boards. Independent powersupplies may be employed to prevent, or substantially prevent, theexistence of a closed conductive loop, thereby preventing (substantiallypreventing or sufficiently preventing) induced current from adverselyaffecting electronic functions. Similarly, to prevent, substantiallyprevent, or sufficiently prevent induced current from interfering withcommand and feedback signals, inner and/or outer circuits may begalvanically isolated. In some embodiments, the galvanic isolation isachieved through the use of infra-red transmitting circuit and receivingcircuit, with one such pair provided for each Coil Control Unit. In thecertain embodiments, control signals from microcontrollers on the CoilControl Unit on the insides of the stators may be galvanically isolatedusing electromagnetic (RF) isolation structures or techniques. Inalternative embodiments (not shown), the galvanic isolation may beachieved through the use of optical, capacitance, induction,electromagnetic, acoustic, mechanical structures or techniques orcombinations thereof adapted for the purpose.

With additional reference to FIG. 9, in the certain embodiments, acurrent of 40 Amperes at between 300 and 450 Volts may be required to besupplied to the electromagnetic coils to achieve maximum power outputfrom the electric motor. In the certain embodiments, electromagneticcoils 22 may be wound up from two separate strips of copper foil 79-82,etc and 83-86, etc around a suitable magnetically permeable core ofsquare cross-sectional shape. The turn of the copper foil windings maybe interleaved with rectangles of grain-oriented silicon steel 87-90,etc specially cut to shape. The steel is often supplied coated with aninsulating compound but, when cut, uninsulated edges are exposed to thecopper foil windings. In practice, in certain applications, this hasonly a minimal effect upon coil function as, because of the lowerresistance of the copper foil, the proportion of total current passingthrough the steel plates is also minimal. The inner ends of the copperfoil windings are connected to insulated conductors 91 which are led outvia the gap between the two the copper foil windings and via suitablylocated apertures in the appropriate the steel plates and, together withthe outer ends 92 of the copper foil windings, are extended as requiredto make the necessary connections between the coils and the IGBTs. Theelectromagnetic coils may be bonded into place in the stators with, andpotted with, for example, a high strength, and high temperature epoxyresin adhesive. The electromagnetic coils may be wound with copper foilto reduce inductance effects and, thereby, to increase the maximum rateof polarity switching. In certain embodiments, a maximum switching rateof 400 Hz being achieved. In certain embodiments, a maximum switchingrate of 100 Hz, 200 Hz, 400 Hz, 500 HZ, 600 Hz or 800 Hz may beachieved. In certain embodiments (not shown) to meet differentoperational parameters, higher or lower switching rates may be achieved.By also reducing back EMF, the voltage required to operate the electricmotor at a given speed may be reduced. In certain embodiments (notshown), the electromagnetic coils may be made by computer-controlleddeposition of copper and a suitable ferromagnetic material to create afacsimile of these embodiments of the coils, the built-up assembly thenbeing given permanent form by sintering. In certain embodiments (notshown) the copper foil part of the electromagnetic coils may be made bycomputer-controlled deposition and electron beam welding or sintering,following which, pre-cut pieces of the grain-oriented silicon steel maybe slid into the apertures between the turns of copper foil. Forexample, copper foil having a thickness of 0.2 millimetres and a maximumeffective width of 25 millimetres is able to carry the desired maximumcurrent of 90 Amperes. Other suitable foil configurations may also beused. With a thickness of 0.23 millimetres, the volume of thegrain-oriented silicon steel within the electromagnetic coil issufficient to allow generation of the necessary magnetic flux strength.The thicknesses of the copper foil and the grain-oriented silicon steelmay be intended as substantially only indicative and, in alternativeembodiments, thicker or thinner materials are optionally employed. Incertain embodiments electromagnetic coils of conventional wire-wound orribbon-wound, bobbin construction may be employed, with an air core orcore made from a suitable magnetically permeable material. Inalternative embodiments, the core may be wound with interleaved layersof graphene and amorphous metals. In another alternative embodiment, theelectromagnetic coils may be made with high-temperature superconductingwindings. The coils may be made with an air core and/or liquid nitrogencooling techniques or means may be employed to maintain a suitableoperating temperature. In alternative embodiments, the core may be edgewound from thin foil maximising packing density.

With additional reference to FIG. 13, in certain embodiments, powerful(or sufficiently powerful) permanent magnets 20, 21 of circularcross-sectional shape may be embedded in the thickness of rotor disc 8as described herein. Suitable slots 76 may be provided in the rotor discto reduce the rotating mass and thereby the angular momentum of therotors and to permit an axial flow of air within the electric motorcasing. With additional reference to FIG. 35, in certain embodiments,powerful permanent magnets 20, 21 may be made more or less trapezoidalin shape and abutting each other with alternating pole orientation. Incertain implementations, one or more of the magnets may be abutting. Incertain applications, the magnets may be made more or less trapezoidalin shape and abutting, substantially abutting, each other withalternating pole orientation. In these embodiments, the radially inneredges of the permanent magnets may be shaped to engage (or communicatewith) a complementary shape formed in the outer edge of the rotor disc,the side edges of the magnets may be shaped to engage (or communicatewith) complementary shaping of adjacent the magnets in an array and themagnets may be retained in place on the rotor disc by a circumferentialrestraining band (not shown) of a high-strength metal material. Thecentral bore 93 of the rotor disc is splined to accommodatecomplementary splining of the differential carrier. In certainembodiments (not shown), the powerful permanent magnets may be shapedapproximately trapezoidal, but with the axis of one or more inclined toa radial passing through it by an angle of between 2.5 and 20 degrees.Other ranges of angles may also be used, for example, an angle ofbetween 2.5 to 5 degrees, 5 to 25 degrees, 5 to 10 degrees or 15 to 20degrees.

In certain embodiments (not shown), individual small circuit boardscontaining power electronics, including the H-bridge, microcontrollerand galvanic isolation means may be placed on the stator disc adjacentone or more of the electromagnetic coils. The circuit boards arepositioned radially outside of the coils, but occupy minimal space anddo not substantially inhibit conductive cooling of the coils. Thereduced conductor length between the power electronics and the powerinput reduces losses due to resistive heating. A ring of clear polymermaterial serves as a light tube to relay control signals to themicrocontrollers. In certain embodiments (not shown), the IGBTs may bemade integrally with the copper of the electromagnetic coils.

With reference to FIG. 36, reflective optical position sensor 95 andHall-effect sensor 96 provide rotor position-related signals tomicroprocessor-based control unit 97. The control unit optionally takesthe form of a microcontroller and/or programmable logic device and/orprogrammable gate array and/or other custom-built unit. From theinterior 100 of the electric motor, the control unit transmits data viagalvanic isolation transmitter 98 to galvanic isolation receiver 102 onthe exterior 101 of the electric motor and thence to microcontrollerunit 105. Similarly, microcontroller unit 105 transmits data to controlunit 97 via galvanic isolation transmitter 103 and galvanic isolationreceiver 99. Separate bi-directional galvanic isolation means may berequired for each the stator. From microcontroller unit 95, data istransmitted to and from a master control unit via conductors 94.Microcontroller unit 95 optionally takes the form of a microcontrollerand/or programmable logic device and/or other purpose-built logicdevice. Control unit 97 communicates with switch drivers 110, 112 viagalvanic isolation unit 111. The galvanic isolation units optionallyemploy one or more of the operating principles described herein and onethe galvanic isolation unit is provided for one or more of the stators.Electrical current is supplied to H-bridge arrangement of IGBTs viaconductors 113, 114 and IGBTs 115, 116, 117, 119 are controlled by theswitch drivers. Electromagnetic coil 118 is connected to the H-bridgesuch that current flow reversal via switching reverses the magneticpolarity of the coil. Electrical current is supplied to DC to DCdown-converter 107 via conductors 106 and the down-converter suppliescurrent to isolated DC to DC down-converter (switching) 108 and isolatedDC to DC down-converter (logic) 109. The down-converter (switching)supplies electrical current to galvanic isolation unit 111, the switchdrivers and the IGBTs and the down-converter (logic) supplies electricalcurrent to control unit 97.

Control unit 97 permits arbitrary switching of one or more of theelectromagnetic coil independently of the other the coils. Usingpulse-width modulation, excitation waveforms can be generated and usedto drive the coil. A wide variety of coil drive profiles can be employedfor the real-time maximisation of efficiency and power output over awide range of RPM and operating temperatures. In certain embodiments ofthe operating method of the electric motor, maximum power may bemaintained by simultaneously powering the electromagnetic coils exceptone, the magnetic polarity of the powered coils being alternating. Theun-powered coil is then re-powered with opposite magnetic polarity suchthat it opposes the magnetic polarity of the preceding the coil(proceeding in the sense of the direction of rotation of the rotors)while the next coil (next in the same rotational sense) is de-powered.The process is continued with each successive coil being de-powered andthen re-powered with opposite polarity to complete a movement of the oneor more permanent magnets from one the coil to the next. Thus, for acomplete rotation of the rotors, the number of the coil de-powerings andre-powerings (with opposite polarity) in the coil array is given by thesquare of the total number of the coils in the array. Where the numberof powered the coils in an array is n, the electric motor is therebyelectromechanically geared, in effect, by a ratio of n:1. In certainembodiments of the operating method of the electric motor, minimum poweris maintained by powering one or more of the electromagnetic coils onlyonce per rotation of the rotor such that each the coil attracts only onethe magnet in the peripheral array of magnets. The electric motor isthereby electromechanically geared, in effect, by a ratio of 1:1.Various sequences or combinations of the coil powerings and de-poweringsmay be employed to achieve a nominated electromechanical gearing.

In certain embodiments (not shown), to reduce cogging effects and/or tomaximise efficiency, the back EMF of an unpowered coil is recorded at arepresentative range of speeds using the analogue-to-digital converterin the microcontroller. During operation, the electromagnetic coils inan array that are normally un-powered may be powered to a level at whichthe magnetic flux generated equals, or substantially equals, the backEMF effect of the coil, thereby neutralizing the magnetic interactionbetween the un-powered coils and the permanent magnets. The mechanism isalso used in regenerative braking permitting the wave to be analysed andthen switched into the correct power planes. The characteristics of theback EMF of the coils may be further analysed during run time for aspecific velocity, power requirement and operating temperature, and anoptimal or near optimal wave generated using pulse-width modulation to,as far as is possible, maximise the efficiency of the electric motor. Inthe certain embodiments, such analysis may be performed automatically,substantially automatically, on a continuous basis, on a discontinuousbasis or other suitable intervals. Pre-computed or partiallypre-computed waveform patterns may be stored in a look-up table and maybe recalled when specific velocity, power requirement, operatingtemperature and, optionally, back EMF, or combinations of these, isdetected. The look-up tables are optionally optimised through the use ofmeta-heuristic algorithms, evolutionary algorithms, traditional,deterministic algorithms, other suitable optimisation techniques orcombinations thereof. In certain embodiments, adaptive control may beimplemented by performing optimisation at run time through the use of anincorporated support vector machine, through the use of neural networktechnology, through the use of fuzzy logic technology, through the useof other suitable application of machine learning technology, throughthe use of suitable adaptive control techniques or through combinationsthereof.

In certain embodiments (not shown), a supply of clean cooling air may besupplied to the interior of the motor casing as required to maintain thestators at a predetermined temperature. The cooling air may be exhaustedvia a suitable valve which maintains a predetermined minimum pressurewithin the casing to prevent, or substantially reduce, ingress ofcontaminants. The supply of cooling air is optionally cooled in arefrigerated heat exchanger before being supplied to the electric motorcasing. In another certain embodiments (not shown), a flow of liquefiedrefrigerant may be supplied to galleries formed in the casing wallsand/or stators of the electric motor and may be allowed to boil off asit takes up heat from the casing. Vapour formed by the cooling processmay be drawn off, compressed and cooled in suitable heat exchangeconfiguration or means to re-liquefy it. In these embodiments, theliquefied refrigerant is optionally a conventional refrigerant or, wherehigh-temperature superconducting coils are employed, liquid nitrogen. Incertain embodiment (not shown), a flow of a suitable liquid coolant maybe circulated through galleries formed in the casing walls and/orstators of the electric motor, heat taken up by the coolant subsequentlybeing dissipated via suitable air-cooled heat-exchange configuration ormeans.

In certain embodiments (not shown), the electric motor may be employedas an electrical generator and one or more of the operating principlesmay be employed to maximise electric power generation efficiency duringrapidly varying generating conditions. Such variable generatingconditions may be, for example, those experienced during regenerativebraking.

In certain embodiments (not shown), where the electric motor is employedas a propulsion unit for an electric vehicle, it optionally drives awheel via a rigid or articulated shaft, it optionally drives a wheel viaone or more chains or belts, it is optionally fixed centrally to avehicle and drives wheels to either side via articulated shafts, or itoptionally generates a flow of pressurised hydraulic fluid to power ahydraulic motor driving one or more wheels.

With reference to FIG. 44, the stator comprising of an upper retainingplate 138, an outer ring 140, an inner ring 141 and a lower retainingplate 139. A series of ferromagnetic cores 55 that may be constructedusing laminated grain oriented silicon steel and a conductor such ascopper wound around the outside 22 are sandwiched between the upper andlower retaining plates. Cut-outs for the cores 144 ensure that the airgap between the rotor and cores are kept to a minimum. Torque istransferred via the upper and lower retaining rings to the outer ringwhich is used to transfer the torque. The resultant cavities between thecores may then be filled with coolant via inlets 142 around theperiphery of the upper retaining plate to the outlets 143 which areoffset by one coil on the lower retaining plate. Coolant may circulatearound the core on its way through the stator. Constrictions on the wallof the inner and outer ring ensure that coolant circles around thecoils. Coolant distribution manifolds (not shown) may be placed abovethe stator and below the stator to supply and collect coolant from acoolant hose. In certain embodiments, where multiple stators are stackedtogether, connecting hoses from the outlets of the previous stator tothe inlet of the next stator may be used. In certain embodiments, thevoid between coils may be filled with thermally conductive resin orceramics to ensure effective cooling to the outer ring. In certainembodiments, fins may be added to the outer ring to maximise the thermalconduction path to a coolant ring in the outer core.

FIG. 45 illustrates a top view of four different exemplary coreconfigurations, with the magnetic field heading into the page, certainembodiments may consist of a rectangular core with the laminates alongthe short edge 126, of a rectangular core with the laminates along thelong edge 127, of a trapazoidal core with the laminates along the edge128, of a square trapezoidal core made up of a series of trapezoidallaminates along the long edge 129. Cores may also be made using aconcertina of laminates, for example, U shapes, I shapes, E shapes, Tshapes, with laminates along both the long and the edge. Cores mayfurther be made by casting or sintering powdered metals or from solidferrous material. In certain embodiments, laminated electrical steels doprovide an advantage in terms of its very high permeability and low eddycurrent losses. The cores may have notches cut out or holes or otherfeatures cut to assist in the stacking and assembly of the cores and inretaining them within the stator.

As shown in FIG. 46, certain embodiments may have cores with coils ofconductors wrapped around the periphery of the core. The copper may beover a bobbin 130, be standard round wire directly around a core 131,rectangular wire around a core 132, rectangular wire edge wound around acore 133, or foil wrapped around a core 134, or a combination of theabove. With reference to FIG. 47, a thinner section of copper 135 may beincluded in certain embodiments where in the event of a short throughthe coil the coil may fuse open preventing large eddy currents thatintroduce unnecessary drag resulting in excessive heat reducing the riskof fire and/or improving overall robustness of the system.

With reference to FIG. 48 in certain embodiments, to facilitate therouting of the wires, two coils are wired side by side providingopposing magnetic fields providing a return path to a single set ofelectronics.

In a certain exemplary embodiment, 46 32 mm by 7.5 mm trapezoidal coresare arranged in a 27 mm stator. Each core is constructed out of 0.23 mmelectrical steel, with small locking features ensuring that the upperand lower retaining plates fabricated out of carbon fibre hold the coresin place. The carbon fibre is attached to a 290 mm outer ring where thetorque is transferred to a set of mounting holes in a similar locationof that of a standard differential. Each core is surrounded with a 0.5mm×3 mm edge wound coil, which is attached to the core using a thermallyconductive adhesive. These cores are glued into the lower retainingplate ensuring no leaking between the core and the retaining plate. A0.5 mm air gap is maintained between the ends of the cores and a platterof 48 trapezoidal magnets of 32 mm by 7 mm, with a thickness of 8 mm.The motor consists of 4 stators interleaved between 5 rotors, with theend rotors having a ferrous end plate to contain the magnetic field.Conductors and ducts for coolant are attached between the stators andarriving at the end where it is connected to drive electronics. Therotors are attached to a differential carrier and the entire device ishoused in an enclosure with thrust bearing at either end. Each coilcontrol unit is connected to 8 coils, one output from the H-bridgeconnected to a coil in the top stator, in series with a coil in thesecond stator, in series with a coil in the third stator, in series witha coil in the bottom stator. At the bottom the coil is connected to anadjacent coil that heads exits at the top of the bottom stator. Thiscoil is attached to the coil on the third stator, which is attached tothe coil in the second stator, which is ultimately connected to the coilin the top stator which is connected to the second connection of theH-bridge.

In the afore mentioned embodiment, each stator magnet pair is able toproduce approximately 750 Nm of torque at 75 Amps RMS. The 4 statorstherefore provide a maximum torque of around 3000 Nm, enough to propel afull sized family Sudan without the need for gearing. The direct liquidcooling may provide continuous cooling at around 50 Amps per mm squared.In certain applications, this embodiment may be rated to operatecontinuously at this torque. At 400 volts this embodiment may reach atop speed of approximately 1500 RPM which is roughly equivalent to 150km/h when driving a standard sedan sized tyre. The total length of thisembodiment is 283 mm and diameter is 290 mm of a size that can fit intothe differential mounting area of a GM Holden Commodore. The weight isapproximately 52 kg including the control electronics and differential.

Method of Design and Manufacture of Certain Exemplary Embodiments

The following examples are included to be illustrative of the variety ofdevices that may be designed and/or manufactures using certain disclosedembodiments. By using the approaches disclosed herein, it iscontemplated that a large number of devices may be designed andconstructed using the technology disclosed herein.

A. In this exemplary method of manufacture, one or more designrequirements are supplied. For example, these requirements mayincluding: size of the device, weight of the device, the maximum powerof the device, the voltage it needs to operate off or generate, the peakcurrent draw or supply (controls the maximum power), the number ofconnections to the power supply (DC, single phase, three phase), therange of angular velocities which the device will run at, the amount oftorque that needs to be delivered, the maximum torque the shaft needs tobe absorbed, or combinations thereof. It is to be understood that otherfeatures may be used in designing and manufacturing the device.

This information may then be processed in the following way: First asuitable module is selected such that it is capable of handling thevoltage required and has enough contacts and switches, (for example, twofor single phase and DC, three for three phase delta, four for threephase star). The power rating of each module is then divided into themaximum power required. The maximum size of the motor is then taken intoconsideration to decide the number of coils that can fit into a circulararrangement; this becomes the size of the platter. The number ofplatters is the number of coils per platter divided into the totalnumber of coils. This number of coils is then checked against themaximum angular velocity ensuring that the inductance of the coil in themodule is not such that it cannot switch at that desired frequency. Ifit is too high, the diameter can be reduced to result in less number ofcoils per platter, resulting in lower frequency of operation. Thisprovides the design information that may then be used to construct thedevice.

B. In this exemplary method of manufacture, one or more specificationsare provided. In this example, the device to be built specifies a motor300 kw as light as possible, preferably under 30 kgs, needs to fit intoa diameter less than 400 mm, as much torque as possible, needs toaccelerate smoothly from stationary, top angular velocity 3000 RPM, 120volts DC, peak current 1500 Amps. The device further specifies hightorque, and small size, and iron core, high power magnets. The DC sourceresults in two inputs.

The next step is to selected iron core 330 v, 90 A single phase modulewhich runs at 120 volts, max current of 90 A, peak power is 10 kw. Thisinformation indicates a minimum of 30 coils. To get maximum torquesmoothing, this specification would indicate one more magnet than coilper platter, Therefore, calculating the number of magnets that can bearranged in a circle of diameter of 400 mm, and find that up to 19 canfit. The magnets selected in this example are an even number so thatthey have alternating fields around the platter, with one less to makeit even, i.e., 18 magnets.

Next the number of coils is selected. In certain applications as in thisone, the number of coils is often a prime number to minimise harmonics,here 17 works, repetition every 34 rotations, harmonic at maximumangular velocity 5 Hz. The maximum frequency of switching coils atmaximum angular velocity is 50 rotations per second times 17 coils,divided by two to take into account positive and negative switch equals425 Hz.

This results in a final configuration of 2 stator platers of 17 coils,total 34 coils total of 320 kw (as one coil per platter is off at anypoint in time), and 3 platters of 18 magnets. Based on this design adevice may be built with a platter stator for coils accommodating 17coils. The next step is to design and manufacture magnetic platteraccommodating 18 coils and to design and manufacture an enclosure andbearing supports to hold the device together. Next assemble the coilsinto stator platters, magnets into rotor platters and build the device.The next step is to modify software to control 17 coils and to switch togeneration mode on breaking.

C. In this exemplary manufacture a specifications is set forth thatspecifies 3 MW, weight is not a consideration, needs to fit into adiameter less than 2000 mm, rotation up to 120 RPM, output voltageshould be 3000 volts RMS. 650 Amps at 50 Hz to match mains, three phase.The specification further specifies high voltage at low speed, specifiesiron core, lots of windings, low current to optimise efficiency. Threephase source therefore specifies three outputs.

This indicates to select iron core 4000 v, 10 A three phase module. Runat 3000 volts, max current of 10 A, peak power is 30 kw. This alsoindicates a minimum of 100 coils. Furthermore, to maximise angularvelocity over the coils to maximise voltage generation, a large diameterplatter is well suited for this application. Since torque smoothness isnot of as much concern, but harmonics in large blades can be of concern,this example indicates one more magnet than coil per platter.

Based on this information, the next step is to calculate the number ofmagnets that can be arranged in a circle of diameter of 2000 mm, findthat up to 104 can fit. Since the number of coils is typically prime tominimise harmonics, 101 works in this example.

This results in a final configuration of, 1 stator platers of 101 coils,and 2 platters of 102 magnets.

The next step is to design and manufacture platter stator for coilsaccommodating 101 coils. Design and manufacture magnetic plattersaccommodating 102 coils. Design and manufacture enclosure and bearingsupports to hold the device together. Assemble the coils into statorplatters, magnets into rotor platters and put it together. Modify thesoftware to control 101 coils and to synchronise to the grid and ensurevoltage is maintained at 3000V RMS.

D. In this exemplary example the specification specifies 1 GW, weightnot a problem, size not a problem, rotation up to 300 RPM, outputvoltage should be 3000 volts RMS 333333 Amps at 50 Hz primary driver ofmains frequency, three phase. There are not many constraints in thisspecification so it is possible to vary several parameters. However,this example uses the process outlined in example C. Another factor isto ensure that diameter is big enough for a shaft that is strong enoughto not shear when 1 GW of rotational power is being put into the shaft.This example may use 512 stacks of 101 coils, total modules 5221.

E. In this exemplary example the specification specifies 2 Kw, maxdiameter 400 mm, rotation up to 300 RPM, input voltage single phase 230v AC 50 hz, price constraint. Choose small modules, air core, 1 amps maxper coil. Total per coil 230 w, require about 10, pick 17 to ensure thatthe dead points in the single phase do not affect the overall poweroutput. To minimise cost combine switches and processor onto singlecircuit board and arrange coils around stator.

Applications

Certain embodiments may be used to convert electrical to mechanicalenergy. In certain embodiments, where the electric motor is employed asa propulsion unit for an electric vehicle the motor may be mounteddirectly into a vehicle to the same or somewhat similar mounting pointas a standard vehicle differential. FIG. 37 illustrates an exemplaryelectrical machine that may be used in traction applications.

In certain embodiments the electrical machine may be used to drive arear wheel drive electric vehicle. FIG. 38 is a top down illustration ofan example of such an installation. The electric motor 53 is mounted atthe rear of the vehicle in the same or similar location as thedifferential. The standard half shafts 121 are connected from the motorto the rear wheels 120. High voltage, high current conductors andcontrol cables can be run along drive shaft tunnel the same pathpreviously occupied by the drive shaft from the battery 122 that may belocated in the location previously occupied by the internal combustionengine and transmission.

In certain embodiments the electrical machine may be used to drive afront wheel drive electric vehicle. FIG. 39 is a top down illustrationof an example of such an installation. The electric motor 53 is mountedat the front of the vehicle in the same or similar location as thedifferential. The standard half shafts 121 are connected from the motorto the front wheels 125. High voltage, high current conductors andcontrol cables connect the battery 122 that may be located in thelocation previously occupied by the internal combustion engine andtransmission.

In certain embodiments the electrical machine may be used to drive anall-wheel drive electric vehicle. FIG. 40 is a top down illustration ofsuch an installation. Two electric motors 53 are mounted at the frontand rear of the vehicle in the same or similar location as thedifferential. The standard half shafts 121 are connected from the motorto the front and rear wheels 120. High voltage, high current conductorsand control cables can be run along drive shaft tunnel the same pathpreviously occupied by the drive shaft from the battery 122 that may belocated in the location previously occupied by the internal combustionengine and transmission.

In certain embodiments the electrical machine may be used to drive asemi trailer truck. FIG. 41 is a top down illustration of such aninstallation. Two electric motors 53 are mounted at the rear of thevehicle in the same or similar location as the differential. Thestandard half shafts 121 are connected from the motor to the two pairsof rear wheels 120. High voltage, high current cables run along the samepath previously occupied by the drive shaft from the battery located inthe location previously occupied by the petrol tanks. These batteriescan be made detachable and can be lifted on and off the truck using aforklift for rapid recharging of a truck.

In an alternative embodiment (not shown), where the electric motor isemployed as a propulsion unit for an electric vehicle, it optionallydrives a wheel via a rigid or articulated shaft, it optionally drives awheel via one or more chains or belts, it is optionally fixed centrallyto a vehicle and drives wheels to either side via articulated shafts, orit optionally generates a flow of pressurised hydraulic fluid to power ahydraulic motor driving one or more wheels.

Furthermore in certain applications, vehicles having electronic controlof braking and/or acceleration, opportunities exist for computer controlof vehicle dynamics, including one or more of the following:

Active cruise control, in which a vehicle maintains a predetermineddistance from a vehicle ahead;

Collision avoidance, where a vehicle brakes automatically to avoid acollision;

Emergency brake assistance, in which a vehicle senses an emergency stopand applies maximum effective braking;

Active software differentials, where individual wheel speed is adjustedin response to other inputs;

Active brake bias, where individual wheel brake effort is adjusted inreal time to maintain vehicle stability;

Brake steer, where individual wheel brake bias is adjusted to assiststeering; and sources of electric current, for traction applications, insustained or intermittent.

Similarly, in other alternative embodiments, the magnets and theelectromagnetic coils may optionally be made in equal numbers, butpreferably with locational asymmetry to prevent or reduce magneticstasis at start-up. In certain applications, the greater centre diameterof the arrays of magnets and the electromagnetic coils, the greater thetorque able to be generated. The arrangement of the electric motorpermits many combinations to be created from standard components—from asingle rotor and stator combination to combinations employing at least10 rotors. The combinations employing larger numbers of rotors andstators may be used in large machines, such as heavy trucks andearthmoving equipment. Other applications may be regenerative brakingand/or power generation.

Adding a capacitor to the module, and configuring the switches and thecoil in either a buck, boost or a buck and boost configuration, thedevice may be driven by software to generate a specific dc voltage tocharge batteries.

In certain embodiments, the torque required to turn the electricalmachine depends on the number of coils generating. The torque requiredto turn the machine maybe in substantially real time (or real time)increased and/or decreased.

Example 1A.1 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one rotor with aplurality of magnets attached to the at least one rotor, wherein the atleast one rotor has an integrated differential, the at least onedifferential permits the rotor to output at least two rotationaloutputs, wherein the at least two rotational outputs are able to move atdifferent rotational velocities to each other, wherein the at least onemodule is in spaced relation to the plurality of the magnets; and the atleast one rotor being in a rotational relationship with the at least onestator, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; wherein the at least one module is capable ofbeing independently controlled; and

wherein the at least one module is capable of being reconfigured basedat least in part on one or more of the following: at least one operatingparameter during operation, at least one performance parameter duringoperation, or combinations thereof.

Example 1A.4 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one platter or rotorwith a plurality of magnets attached to the at least one platter orrotor, wherein the at least one rotor has an integrated differential,the at least one differential permits the rotor to output at least tworotational outputs, wherein the at least two rotational outputs are ableto move at different rotational velocities to each other, wherein the atleast one module is in spaced relation to the plurality of the magnets;and the at least one platter or rotor being movement relationship withthe at least one stator, wherein the quantity and configuration of theat least one module in the electrical machine is determined based inpart on one or more operating parameters; wherein the at least onemodule is capable of being independently controlled; and wherein the atleast one module is capable of being reconfigured based at least in parton one or more of the following: at least one operating parameter duringoperation, at least one performance parameter during operation, orcombinations thereof.

Example 1A.5 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one platter or rotorwith a plurality of magnetic induction loops, attached to the at leastone platter or rotor, wherein the at least one platter or rotor has anintegrated differential, the at least one differential permits the rotorto output at least two rotational outputs, wherein the at least tworotational outputs are able to move at different rotational velocitiesto each other, wherein the at least one module is in spaced relation tothe plurality of the magnetic induction loops; and the at least oneplatter or rotor being movement relationship with the at least onestator, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters;

wherein the at least one module is capable of being independentlycontrolled; and

wherein the at least one module is capable of being reconfigured basedat least in part on one or more of the following: at least one operatingparameter during operation, at least one performance parameter duringoperation, or combinations thereof.

Example 1A.6 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one platter or rotorwith a plurality of magnetic reluctance projections attached to the atleast one platter or rotor, an integrated differential coupled to atleast one of the at least one platters or rotors, the at least oneintegrated differential permitting the at least one platter or rotor tooutput at least two rotational outputs to corresponding shafts, whereinthe at least two rotational outputs are able to move the shafts atdifferent rotational velocities to one another, wherein the at least onemodule is in spaced relation of a plurality of magnetic reluctanceprojections; and the at least one platter or rotor being movementrelationship with the at least one stator, wherein the quantity andconfiguration of the at least one module in the electrical machine isdetermined based in part on one or more operating parameters; whereinthe at least one module is capable of being independently controlled;and wherein the at least one module is capable of being reconfiguredbased at least in part on one or more of the following: at least oneoperating parameter during operation, at least one performance parameterduring operation, or combinations thereof.

Example 1A.7 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one rotor with aplurality of magnets attached to the at least one rotor, an integrateddifferential coupled to at least one of the at least one rotors, the atleast one integrated differential permitting the at least rotor tooutput at least two rotational outputs to corresponding shafts, whereinthe at least two rotational outputs are able to move the shafts atdifferent rotational velocities to one another wherein the at least onemodule is in spaced relation to the plurality of the magnets; and the atleast one rotor being in a rotational relationship with the at least onestator.

Example 1A.9 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one platter or rotorwith a plurality of magnets attached to the at least one platter orrotor, wherein the at least one rotor has an integrated differential,the at least one differential permits the rotor to output at least tworotational outputs, the at least one rotor is attached to at least onecrown wheel that is driven by at least one drive shaft, wherein the atleast two rotational outputs are able to move at different rotationalvelocities to each other, wherein the at least one module is in spacedrelation to the plurality of the magnets; and the at least one platteror rotor being movement relationship with the at least one stator.

Example 1A.10 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one platter or rotorwith a plurality of magnets attached to the at least one platter orrotor, an integrated differential coupled to at least one of the atleast one platters or rotors, the at least one integrated differentialpermitting the at least platter or rotor to output at least tworotational outputs to corresponding shafts, wherein the at least tworotational outputs are able to move the shafts at different rotationalvelocities to one another, wherein the at least one module is in spacedrelation to the plurality of the magnets; and the at least one platteror rotor being movement relationship with the at least one stator.

Example 1A.11 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator, at least one platter or rotorwith a plurality of magnetic reluctance projections attached to the atleast one platter or rotor, an integrated differential coupled to atleast one of the at least one platters or rotors, the at least oneintegrated differential permitting the at least platter or rotor tooutput at least two rotational outputs to corresponding shafts, whereinthe at least two rotational outputs are able to move the shafts atdifferent rotational velocities to one another, wherein the at least onemodule is in spaced relation to the plurality of magnetic reluctanceprojections; and the at least one platter or rotor being movementrelationship with the at least one stator.

Example 1A.12 An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one platter or rotorwith a plurality of magnetic induction loops attached to the at leastone platter or rotor, an integrated differential coupled to at least oneof the at least one platters or rotors, the at least one integrateddifferential permitting the at least platter or rotor to output at leasttwo rotational outputs to corresponding shafts, wherein the at least tworotational outputs are able to move the shafts at different rotationalvelocities to one another, wherein the at least one module is in spacedrelation to the plurality of magnetic induction loops; and the at leastone platter or rotor being movement relationship with the at least onestator.

Example 2A.1 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; wherein the at least one module is capable ofbeing independently controlled; and wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, or combinationsthereof.

Example 2A.2 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters.

Example 2A.3 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the at least one module is capable of beingindependently controlled.

Example 2A.4 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the at least one module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, at least one performanceparameter during operation, or combinations thereof.

Example 2A.5 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; and wherein the at least one module iscapable of being independently controlled.

Example 2A.6 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the at least one module is capable of beingindependently controlled; and wherein the at least one module is capableof being reconfigured based at least in part on one or more of thefollowing: at least one operating parameter during Operation, at leastone performance parameter during operation, or combinations thereof.

Example 2A.7 The electrical machine of one or more of the examples 1A.7to 1A.12, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; and wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, or combinationsthereof.

Example 3A The electrical machine of one or more of the above Aexamples, wherein the one or more operating parameters are selected fromone or more of the following: maximum angular velocity, average angularvelocity, minimum angular velocity, maximum power output, average poweroutput, minimum power output, maximum input voltage, average inputvoltage, minimum input voltage, maximum generation voltage, averagegeneration voltage, minimum generation voltage, peak input current,average input current, minimum input current, maximum generationcurrent, average generation current, minimum generation current, maximumtorque, average torque, activation sequence, minimum torque, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, rate of deceleration during breaking,diameter of the shaft, maximum radius of the electrical machine, maximumlength of the electrical machine, maximum depth of the electricalmachine, maximum height of the machine, maximum slide distance, minimumslide distance, maximum weight of the machine, minimum weight of themachine, maximum resistive power loss, unit redundancy and overallprice.

Example 4A.1 The electrical machine of one or more of the above Aexamples, wherein the at least one operating parameter during operationmay be selected from one or more of the following: maximum angularvelocity, average angular velocity, minimum angular velocity, maximumpower output, average power output, minimum power output, maximum inputvoltage, average input voltage, minimum input voltage, maximumgeneration voltage, average generation voltage, minimum generationvoltage, shape and frequency of generated voltage, peak input current,average input current, minimum input current, maximum generationcurrent, average generation current, minimum generation current, maximumtorque, average torque, minimum torque, torque smoothness, activationsequence, rate of acceleration, order of accuracy of hold angle,minimising the variation of angular velocity, rate of decelerationduring breaking, diameter of the shaft, maximum radius of the electricalmachine, maximum length of the electrical machine, maximum depth of theelectrical machine, maximum height of the machine, maximum slidedistance, minimum slide distance, maximum weight of the machine, minimumweight of the machine, maximum resistive power loss, unit redundancy andoverall price.

Example 4A.2 The electrical machine of one or more of the above Aexamples, wherein the at least one performance parameter duringoperation may be selected from one or more of the following: maximumangular velocity, maximum power output, deviation from output voltageduring generation, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave, andaccuracy of generated frequency.

Example 4A.3 The electrical machine of one or more of the above Aexamples, wherein one or more performance parameters during operationmay be selected from one or more of the following: maximum angularvelocity, maximum power output, deviation from output voltage duringgeneration, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave, andaccuracy of generated frequency.

Example 4A.4 The electrical machine of one or more of the above Aexamples, wherein the at least one module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, wherein the at least oneoperating parameter during operation may be selected from one or more ofthe parameters listed in example 4A.3; at least one performanceparameter during operation, wherein the at least one performanceparameter during operation may be selected from one or more of theparameter listed in example 4A.2; or combinations thereof.

Example 5A The electrical machine of one or more of the above Aexamples, wherein the at least one electromagnetic coil comprises aplurality of electromagnetic coils that are in a substantially circulararrangement or an axial flux arrangement.

Example 6A The electrical machine of one or more of the above Aexamples, wherein the at least one electromagnetic coil and theplurality of magnets are in an angular or a radially offset arrangement.

Example 7A The electrical machine of one or more of the above Aexamples, wherein the number of coils in the at least oneelectromagnetic coil is not the same number as the number of magnetic inthe plurality magnets.

Example 8A The electrical machine of one or more of the above Aexamples, wherein the number of coils in the plurality ofelectromagnetic coils is the same number as the number of magnetic inthe plurality of magnets and the spaced relation between the pluralityof electromagnetic coils and the plurality of magnets is geometricallyoffset to prevent concentric alignment.

Example 9A The electrical machine of one or more of the above Aexamples, wherein the number of coils in the at least oneelectromagnetic coil is at least one less than the number of magnets inthe plurality of magnets.

Example 10A The electrical machine of one or more of the above Aexamples, wherein the plurality of electromagnetic coils are arranged inan axially aligned arrangement with the plurality of magnets.

Example 11A The electrical machine of one or more of the above Aexamples, wherein the plurality of electromagnetic coils are arranged inaxially misaligned arrangement by at least 5, 10, 15, 20, 25, 30, 35,40, or 45 degrees with the plurality of magnets.

Example 12A The electrical machine of one or more of the above Aexamples, wherein the plurality of electromagnetic coils are axiallyaligned with the at least one stator and the plurality of magnets areaxially aligned with the at least one rotor.

Example 13A The electrical machine of one or more of the above Aexamples, wherein the plurality of electromagnetic coils are substantialperpendicular or perpendicular with the at least one stator and theplurality of magnets coils are substantial perpendicular orperpendicular with the at least one rotor.

Example 14A The electrical machine of one or more of the above Aexamples, further comprising an enclosure that is mechanicallysufficient to suitably resist deformation from mechanical forces when inoperation.

Example 15A The electrical machine of one or more of the above Aexamples, further comprising an enclosure that is thermally conductive.

Example 16A The electrical machine of one or more of the above Aexamples, further comprising an enclosure that may be used as aconductor for one or more electronic switches.

Example 17A.1 The electrical machine of one or more of the above Aexamples, wherein the power to weight ratio of the electrical machine isat least 0.01, 0.1, 0.25, 0.5, 1, 2, 3, 3.4 4, 4.5 5, 6, 7, 8, 8.4 9, 1011, 12, 13, 14 or 15 kilowatts per kilogram.

Example 17A.2 The electrical machine of one or more of the above Aexamples, wherein the power to weight ratio of the electrical machine isat between 10 to 1, 15 to 3, 10 to 0.5, 9 to 4, 5 to 0.01, 3.4 to 6 or8.4 to 3.4 kilowatts per kilogram.

Example 18A.1 The electrical machine of one or more of the above Aexamples, wherein the power to weight ratio of the electrical machine is10%, 25%, 50%, 100%, 125%, 150%, 200%, 250%, 300%, 500% or 1000% greaterthan a brushless permanent magnet three phase electrical machine with asubstantially similar size and weight.

Example 18A.2 The electrical machine of one or more of the above Aexamples, wherein the power to weight ratio of the electrical machine isbetween 10% to 1000%, 10% to 25%, 10% to 100%, 25% to 50%, 25% to 150%,50% to 250%, 50% to 100%, 100% to 125%, 100% to 250%, 125% to 150%, 150%to 300%, 200% to 1000%, 250% to 500%, 250% to 1000% or 500% to 1000%greater than a brushless permanent magnet three phase electrical machinewith a substantially similar size and weight.

Example 19A.1 The electrical machine of one or more of the above Aexamples, further comprising at least one sensor to detect absolute orrelative position of the at least one rotor; and at least one controlsystem which, in response to inputs from the one or more of thefollowing: the at least one sensor, at least one power command, at leastone mode command comprising one or more of the following: at least onedrive, generate, braking and hold command and at least one rotationaldirection command.

Example 19A.2 The electrical machine of example 19A.1, wherein the atleast one control system is configured to be in a drive configuration orhas the at least one drive mode command, the at least one control systemactivates at least one switch which energies one or more of the magneticcoils to attract and repel the magnets for the purpose of generatingmotion.

Example 19A.3 The electrical machine of example 19A.1, wherein theelectrical machine is configured to be in a generation configuration orhas at least one mode command to generate power, the at least onecontrol system activates at least one switch which connects one or morecoils to the external power rails.

Example 19A.4 The electrical machine of example 19A.1, wherein theelectrical machine is configured to be in a braking configuration or hasthe at least one mode command to brake, the at least one control systemactivates at least one switch which connects one or more of the magneticcoils terminals together to oppose motion.

Example 19A.5 The electrical machine of example 19A.1, wherein theelectrical machine is configured to be in a holding configuration or hasthe at least one mode command to hold, the at least one control systemactivates at least one switch energises one or more of the magneticcoils to attract and repel magnets for the purpose of stopping motion.

Example 20A.1 The electrical machine of one or more of the above Aexamples, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameter on a substantiallycontinuous basis during operating periods.

Example 20A.2 The electrical machine of one or more of the above Aexamples, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.

Example 21A The electrical machine of one or more of the above Aexamples, wherein the electrical machine is capable of being operatedefficiently over 50%, 60%, 70%, 80%, 90%, 95%, 98% or 100% of the RPMranges of the electrical machine.

Example 22A.1 The electrical machine of one or more of the above Aexamples, wherein the electrical machine has a power density of about100, 500, 1000, 2000, 5000, 10000 or 20000 kw/meter cubed.

Example 22A.2 The electrical machine of one or more of the aboveexamples, wherein the electrical machine has a power density of at least100, 500, 1000, 2000, 5000, 10000, or 20000 kw/meter cubed.

Example 22A.3 The electrical machine of one or more of the above Aexamples, wherein the electrical machine has a power density of between100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000to 15,000, 10,000 to 30,000 or 10,000 to 20,000 kw/meter cubed.

Example 23A.1 The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one operating parameter ofthe electrical machine may be reconfigured in substantially real time.

Example 23A.2 The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one operating parameter,the at least one performance parameter or combinations thereof of theelectrical machine may be reconfigured in substantially real time.

Example 24A The electrical machine of one or more of the above Aexamples, wherein the at least one control system provides individualcontrol over at least 30%, 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% ofthe plurality of coils.

Example 25A The electrical machine of one or more of the above Aexamples, wherein the at least one operating parameter of the electricalmachine may be reconfigured in substantially real time and the optimalsettings for performance determined and implemented across 50%, 60%,70%, 80%, 90%, 95%, 98% or 100% of one or more of the following:operating speeds and loads.

Example 26A.1 The electrical machine of one or more of the above Aexamples, wherein the timing of the plurality of coils may bereconfigured in substantially real time in order to continuouslyoptimize the timing of the plurality of coils.

Example 26A.2 The electrical machine of one or more of the above Aexamples, wherein the timing of the at least one coil may bereconfigured in substantially real time in order to continuouslyoptimize the timing of the at least one of coil.

Example 27A.1 The electrical machine of one or more of the above Aexamples, wherein the total number of permanent magnets may be reducedby a minimum of 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60% or70% and still provide comparable power output to a brushless permanentmagnet three phase electrical machine.

Example 27A.2 The electrical machine of one or more of the above Aexamples, wherein the total number of permanent magnets may be reducedby a minimum of between 10% to 70%, 10% to 25%, 20% to 50%, 15% to 35%,20% to 55%, 25% to 50%, 30% to 60%, 35% to 50%, 40% to 60%, 45% to 70%or 50% to 70%, and still provide comparable power output to a brushlesspermanent magnet three phase electrical machine.

Example 28A.1 The electrical machine of one or more of the above Aexamples, wherein the plurality of coils has about 1000, 500, 100, 50,40, 35, 30 25, 20, 15, 10 or 5, times less variation in torque through arotation than a brushless permanent magnet three phase electricalmachine with comparable power output.

Example 28A.2 The electrical machine of one or more of the above Aexamples, wherein the plurality of coils has between 1000 to 100, 1000to 100, 500 to 100, 500 to 20, 100 to 5, 100, to 30, 50 to 10, 40 to 15,35 to 10, 30 to 15, 25 to 10, 20 to 5, 15 to 5 or 10 to 5, times lessvariation in torque through a rotation than a brushless permanent magnetthree phase electrical machine with comparable power output.

Example 29A.1 The electrical machine of one or more of the above Aexamples, wherein the material savings in the magnets would be at least10%, 15%, 20%, 30%, 40%, 50% or 60% of a brushless permanent magnetpermanent magnet three phase electrical machine with comparable poweroutput.

Example 29A.2 The electrical machine of one or more of the above Aexamples, wherein the material savings in the magnets would be between10% to 60%, 10% to 30%, 15% to 30%, 20% to 50%, 30% to 50%, 40% to 60%or 50% to 70% of brushless permanent magnet three phase electricalmachine with comparable power output.

Example 30A.1 The electrical machine of one or more of the above Aexamples, wherein the material savings in the copper would be at least10%, 15%, 20%, 30%, 40%, 100%, 200% or 1000% more than that of a similarbrushless permanent magnet 3 phase electrical machine with similarresistive power loss per power output.

Example 30A.2 The electrical machine of one or more of the above Aexamples, wherein the material savings in the copper would be between10% to 100%, 15% to 40%, 20% to 100%, 20% to 200%, 30% 1000%, 40% to150%, 100% to 200%, 200% to 500%, 200% to 1000% or 500% to 1000% morethan that of a similar brushless permanent magnet 3 phase electricalmachine with similar resistive power loss per power output.

Example 31A The electrical machine of one or more of the above Aexamples, wherein the stator can be manufactured out of aluminium,steel, copper, polyethylene, acrylic, polymer reinforced carbon fibre,polymer reinforced fiberglass, graphene, other metallic, plastic and/orcomposite materials or combinations thereof, and the stator has suitablerigidity.

Example 32A The electrical machine of one or more of the above Aexamples, wherein the rotor can be manufactured out of aluminium, steel,copper, polyethylene, acrylic, polymer reinforced carbon fibre, polymerreinforced fiberglass, graphene, other metallic, plastic and/orcomposite materials or combinations thereof and the rotor has suitablerigidity.

Example 33A The electrical machine of one or more of the above Aexamples, wherein the enclosure can be manufactured out of aluminium,steel, copper, polyethylene, acrylic, polymer reinforced carbon fibre,polymer reinforced fiberglass, graphene, other metallic, plastic and/orcomposite materials or combinations thereof and the enclosure hassuitable rigidity.

Example 34A The electrical machine of one or more of the above Aexamples, wherein the magnetic field in the rotor or slider can beproduced through the use of rare earth or other conventional forms ofpermanent magnets.

Example 35A The electrical machine of one or more of the above Aexamples, wherein the plurality magnetic field generators are one ormore of the following: loops or coils of a metallic material that inducea current in the loops to produce a magnetic field.

Example 36A The electrical machine of one or more of the above Aexamples, wherein the plurality magnetic field generators are strips offerromagnetic material that redirect magnetic fields.

Example 37A.1 The electrical machine of one or more of the above Aexamples, wherein to save space, cost or both, the at least one switchesfor the at least one module is fabricated on the same circuit board.

Example 37A.2 The electrical machine of one or more of the aboveexamples, wherein, the at least one switch for the at least one moduleis fabricated on the same circuit board.

Example 38A.1 The electrical machine of one or more of the above Aexamples, wherein to save space, cost or both, at least oneelectromagnetic coil of the at least one module is fabricated as asingle unit.

Example 38A.2 The electrical machine of one or more of the above Aexamples, wherein the at least one electromagnetic coil of the at leastone module is fabricated as a single unit.

Example 39A The electrical machine of one or more of the above Aexamples, wherein the at least one module has an enclosure that may beattached to one or more other modules in order to construct the at leastone stator without having to have a separate stator structure.

Example 40A The electrical machine of one or more of the above Aexamples, wherein one or more of the plurality of magnets have anenclosure around them such that one or more of the magnets may beattached to one or more other magnets to create at least one rotor thatmay be connected to at least one shaft.

Example 41A The electrical machine of one or more of the above Aexamples, wherein the physical location of the at least one module inreference to the other modules and the at least one stator is hard codedinto the control software.

Example 42A The electrical machine of one or more of the above Aexamples, wherein the physical location of the at least one module inreference to one or more of the other modules and the at least onestator is encoded by one or more sequences of electrical connectionsthat may be constructed using switches, solder bridges, jumpers,connectors, cutting printed circuit tracks, other suitable ways ofmaking and breaking electrical connections, or combinations thereof.

Example 43A The electrical machine of one or more of the above Aexamples, wherein the physical location of the at least one module inreference to one or more of the other modules and the at least onestator is detected by the location that the at least one module isinserted into in the at least one stator by a series of electricalcontacts, optical reflections, magnetic forces or combinations thereofencoding the position of the module.

Example 44A The electrical machine of one or more of the above Aexamples, that are one or more combinations of examples 41A, 42A and43A.

Example 45A The electrical machine of one or more of the above Aexamples, wherein the at least one electromagnetic coil is arrangedaround the periphery of the at least one stator.

Example 46A The electrical machine of one or more of the above Aexamples, further comprising at least one shaft.

Example 47A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnets are arranged around theperiphery of the at least one rotor and have substantially the samecentre diameter as that of one or more of the at least oneelectromagnetic coil, a plurality of the at least one electromagneticcoils, or a substantial portion of the plurality of the at least oneelectromagnetic coils.

Example 49A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnets are arranged around theperiphery of the at least one rotor and have substantially the samecentre diameter as that of one or more of the at least oneelectromagnetic coil, a plurality of the at least one electromagneticcoils, or a substantial portion of the plurality of the at least oneelectromagnetic coils and two or more of the magnets have alternatingpole orientation.

Example 50A The electrical machine of one or more of the above Aexamples, wherein two or more of the magnets of the plurality of magnetshave alternating pole orientation.

Example 51A The electrical machine of one or more of the above Aexamples, wherein there is a gap between the at least one stator and theat least one rotor.

Example 52A.1 The electrical machine of one or more of the above Aexamples, wherein the relative weight of the at least oneelectromagnetic coil is approximately equal to an inverse of the totalnumber of coils as compared to a single phase electrical machine with asubstantially similar resistive loss.

Example 52A.2 The electrical machine of one or more of the above Aexamples, wherein the electrical machine has (n) coils and a weight ofapproximately 1/(n−1) to 1/(n+1) relative to a single phase motor withsubstantially the similar resistive loss.

Example 53A.1 The electrical machine of one or more of the above Aexamples, wherein one or more module coil activation sequences arecomputed during operation of the electrical machine and the order of theat least one module activating being sequentially based on its geometricposition in a module array.

Example 53A.2 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is computed duringmachine operation the order of modules activating being sequentiallybased on their geometric position in the module array.

Example 54A.1 The electrical machine of one or more of the above Aexamples, wherein the one or more module coil activation sequence iscomputed during electrical machine operation, the order of at least onemodule activating being based at least in part on sensor feedback;

Example 54A.2 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is computed duringmachine operation, the order of modules activating being based uponsensor feedback.

Example 55A.1 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is computed duringmachine operation, the order of modules activating being determined by asequence pattern.

Example 55A.2 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is computed duringmachine operation and the order of the at least one modules activatingbeing determined by at least in part one or more sequence patterns.

Example 56A.1 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is computed duringmachine operation and the order of modules activating being determinedbased at least in part on one or more optimal power usage scenarios.

Example 57A.2 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is predeterminedand stored, and the sequence is sourced at least in part from sensorfeedback.

Example 58A. 1 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is predeterminedand stored, the nature of the sequence being sourced from precomputeddata stored within the module.

Example 58A.2 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is predeterminedand stored, and the nature of the sequence being sourced at least inpart from precomputed data stored within the module.

Example 59A.1 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is predeterminedand stored, the nature of the sequence being sourced from externalmodules over a communications bus.

Example 59A.2 The electrical machine of one or more of the above Aexamples, wherein the module coil activation sequence is predeterminedand stored, and the nature of the sequence being sourced from one ormore external modules over one or more communications busses.

Example 60A The electrical machine of one or more of the above examples,wherein the module coil activation sequence is determined based on oneor more of the above A examples, sourced based on one or more of theabove examples or both.

Example 61A.1 The electrical machine of one or more of the above Aexamples the total number of powered coils in the active sequence canvary during operation from the total number of coils, to none.

Example 61A.2 The electrical machine of one or more of the above Aexamples, wherein the total number of the at least one electromagneticcoils powered in the active sequence may vary during operation from thetotal number of coils, to none.

Example 62A The electrical machine of one or more of the above Aexamples, wherein the number of the at least one electromagnetic coilsactive may or may not be based upon sensor feedback.

Example 63A The electrical machine of one or more of the above Aexamples, wherein the control of the electrical machine is centralisedon at least one control module.

Example 64A The electrical machine of one or more of the above Aexamples, wherein the control of the electrical machine is distributedto one or more of the modules, with one or more modules actingindependently.

Example 65A The electrical machine of one or more of the above Aexamples, wherein the control of the electrical machine is arbitratedbetween two or more designated modules.

Example 66A The electrical machine of one or more of the above Aexamples, wherein one or more modules may be individually removed,added, or replaced during operation of the machine, withoutsubstantially affecting the operational state of the machine.

Example 67A The electrical machine of example 66A, wherein 1, 2, 3, 4,5, 6, 7, 8, 9 or 10 modules may be individually removed, added, orreplaced during operation of the machine, without substantiallyaffecting the operational state of the machine.

Example 68A The electrical machine of example 66A, wherein 1, 2, 3, 4,5, 6, 7, 8, 9 or 10 modules may be individually removed, added, orreplaced during operation of the machine, without substantiallyaffecting the operational state of the machine.

Example 69A The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one modules may beindividually removed, added, or replaced while the machine is poweredoff.

Example 70A The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one operational parameterused by individual modules are tuned dynamically during operation of theelectrical machine, based at least in part on sensor feedback.

Example 71A The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one operational parameterused by individual modules are tuned dynamically during operation of theelectrical machine, and the tuning methods used may or may not involvethe use of machine learning algorithms.

Example 72A The electrical machine of one or more of the above Aexamples, wherein the machines control system permits the motor tooperate in both the clockwise and counterclockwise direction withrespect to the rotational axis of the primary output or input.

Example 73A The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one modules furthercomprises one or more safety systems implemented in hardware, software,or both to allow automatic power cut-off with respect to the coil, inthe event of a feedback based event.

Example 74A The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one modules furthercomprises one or more external power safety cut-off control inputs onone or more of the modules. The inputs taking the form of tactileswitches or digital touch panels or communications buses, the cut offsbeing designed such that they bypass the primary controller in eachmodule.

Example 75A The electrical machine of one or more of the above Aexamples, wherein one or more of the at least one modules furthercomprises one or more external power safety cut-off control inputs onone or more of the modules and the inputs may be one or more of thefollowing: tactile switches, digital touch panels, communications buses,or combinations thereof, wherein the cut offs are designed such thatthey bypass the primary controller in one or more of the at least onemodule.

Example 76A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises at least onesensor for detecting the back EMF from the modules coil in order toreduce cogging effects to improve efficiency, and the back-EMF of anunpowered coil is recorded at a representative range of speeds using theanalogue-to-digital converter in at least one coil control unit duringoperation; the un-powered coil is then powered to a voltage thatsubstantially negates the back-EMF thereby neutralizing the magneticinteraction between the un-powered coil and the magnets; and optionalthis procedure may be repeat for one or more coils in the array in orderto reduce cogging effects.

Example 77A Any of the above A examples implemented in hardware,software, or combinations thereof.

Example 78A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting the voltage across the at least one module's coil.

Example 79A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting the current flowing across the at least onemodule's coil.

Example 80A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting the back EMF from the at least one module's coil.

Example 81A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting the absolute or relative position of the machine'sthe at least one rotor in relation to the at least one module'sposition.

Example 82A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting the velocity of the machines the at least onerotor in relation to the at least one module's position.

Example 83A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting the thermal temperature around the at least onemodule or other surfaces within the electrical machine.

Example 84A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting one or more of the following: the magnitude, theangle and the direction of at least one magnetic field.

Example 85A The electrical machine of one or more of the above Aexamples, wherein the at least one module further comprises one or moresensors for detecting accelerations, for the purpose of vibrationdetection.

Example 86A A method of use that uses the electrical machine of one ormore of the above A examples or combinations of the features disclosedherein.

Example 87A A system that uses the electrical machine of one or more ofthe above A examples or combinations of the features disclosed herein.

Example 88A A module that incorporates the features of one or more ofthe above A examples or combinations of the module features disclosedherein.

Example 89A A control systems for an electrical machine thatincorporates the features of one or more of the above A examples orcombinations of the control features disclosed herein.

Example 90A A control systems for a module that incorporates thefeatures of one or more of the above A examples or combinations of thecontrol features disclosed herein.

Example 91A The electrical machine of one or more of the above Aexamples, wherein at least one adaptive control is implemented byperforming optimisation during machine operation through the use of oneor more of the following: at least one support vector machine, neuralnetwork algorithm, a fuzzy logic algorithm, of machine learningalgorithms and through the use of other suitable adaptive controltechniques.

Example 92A The electrical machine of one or more of the above Aexamples, wherein the at least one stator is a substantial portion ofthe stators contained in the electrical machine.

Example 93A The electrical machine of one or more of the above Aexamples, wherein the at least one stator is all of the statorscontained in the electrical machine.

Example 94A The electrical machine of one or more of the above Aexamples, wherein the at least one module is a substantial portion ofthe modules contained in the electrical machine.

Example 95A The electrical machine of one or more of the above Aexamples, wherein the at least one module is all of the modulescontained in the electrical machine.

Example 96A The electrical machine of one or more of the above Aexamples, wherein the at least one electromagnetic coil is a substantialportion of the electromagnetic coils contained in the electricalmachine.

Example 97A The electrical machine of one or more of the above Aexamples, wherein the at least one electromagnetic coil is all of theelectromagnetic coil contained in the electrical machine.

Example 98A The electrical machine of one or more of the above Aexamples, wherein the at least one switch is a substantial portion ofthe switches contained in the electrical machine.

Example 99A The electrical machine of one or more of the above Aexamples, wherein the at least one switch is all of the switchescontained in the electrical machine.

Example 100A The electrical machine of one or more of the above Aexamples, wherein the at least one rotor is a substantial portion of therotors contained in the electrical machine.

Example 101A The electrical machine of one or more of the above Aexamples, wherein the at least one rotor is all of the rotors containedin the electrical machine.

Example 102A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnets is a substantial portion ofthe magnets contained in the electrical machine.

Example 103A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnets is all of the magnetscontained in the electrical machine.

Example 104A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnetic induction loops is asubstantial portion of the magnetic induction loops contained in theelectrical machine.

Example 105A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnetic induction loops is all ofthe magnetic induction loops contained in the electrical machine.

Example 106A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnetic reluctance projections is asubstantial portion of the magnetic reluctance projections contained inthe electrical machine.

Example 107A The electrical machine of one or more of the above Aexamples, wherein the plurality of magnetic induction loops is all ofthe magnetic induction loops contained in the electrical machine.

Example 109A The electrical machine of one or more of the above Aexamples, wherein the plurality of stators is a substantial portion ofthe stators contained in the electrical machine.

Example 110A The electrical machine of one or more of the above Aexamples, wherein the plurality of stators is all of the statorscontained in the electrical machine.

Example 111A The electrical machine of one or more of the above Aexamples, wherein the plurality of modules is a substantial portion ofthe modules contained in the electrical machine.

Example 112A The electrical machine of one or more of the above Aexamples, wherein the plurality of modules is all of the modulescontained in the electrical machine.

Example 113A The electrical machine of one or more of the above Aexamples, wherein the plurality of rotors is a substantial portion ofthe rotors contained in the electrical machine.

Example 114A The electrical machine of one or more of the above Aexamples, wherein the plurality of rotors is all of the rotors containedin the electrical machine.

Example 1B An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one rotor with aplurality of magnets attached to the at least one rotor, wherein the atleast one module is in spaced relation to the plurality of the magnets;an integrated differential coupled to at least one of the at least onerotors, the at least one integrated differential permitting the at leastone rotor to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocities relative to one another, andthe at least one rotor being in a rotational relationship with the atleast one stator; wherein the quantity and configuration of the at leastone module in the electrical machine is determined based in part on oneor more operating parameters; wherein the at least one module is capableof being independently controlled; wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, and combinationsthereof; and wherein the electrical machine is configured to fit into ahousing and that can be retrofitted into a conventional vehicle byreplacing the differential.

Example 2B An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one rotor with aplurality of magnets attached to the at least one rotor, wherein the atleast one module is in spaced relation to the plurality of the magnets;an integrated differential coupled to at least one of the at least onerotors, the at least one integrated differential permitting the at leastone rotor to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocities relative to one another, andthe at least one rotor being in a rotational relationship with the atleast one stator; wherein the quantity and configuration of the at leastone module in the electrical machine is determined based in part on oneor more operating parameters; wherein the at least one module is capableof being independently controlled; wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, and combinationsthereof; and wherein the electrical machine is configured to fit into ahousing and that can be located, in substantially that same positionwhere a differential would otherwise be located in a vehicle or othermachine.

Example 3B An electrical machine comprising: a plurality of stators; aplurality of modules comprising at least one electromagnetic coil and atleast one switch and being attached to at least one of the plurality ofstators; a plurality of rotors with a plurality of magnets attached toat least one of the plurality of rotors, the plurality of rotors areable to move independently to one another to produce a differentialoutput that permits the electric machine to output at least tworotational outputs to corresponding shafts, wherein the at least tworotational outputs are able to move the shafts at different rotationalvelocity's relative to one another, and the plurality of modules are inspaced relation to the plurality of the magnets; and the plurality ofrotors being in a rotational relationship with the plurality of stators;wherein the quantity and configuration of the plurality of modules inthe electrical machine is determined based in part on one or moreoperating parameters; wherein the plurality of modules are capable ofbeing independently controlled, and wherein the plurality of modules arecapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, and atleast one performance parameter during operation; and wherein theelectrical machine is configured to fit into a housing and that can belocated in substantially that same position where a differential wouldotherwise be located in a vehicle or other machine.

Example 4B An electrical machine comprising: a plurality of stators; aplurality of modules comprising at least one electromagnetic coil and atleast one switch and being attached to at least one of the plurality ofstators; a plurality of rotors with a plurality of magnets attached toat least one of the plurality of rotors, the plurality of rotors areable to move independently to one another to produce a differentialoutput that permits the electric machine to output at least tworotational outputs to corresponding shafts, wherein the at least tworotational outputs are able to move the shafts at different rotationalvelocity's relative to one another, and the plurality of modules are inspaced relation to the plurality of the magnets; and the plurality ofrotors being in a rotational relationship with the plurality of stators;wherein the quantity and configuration of the plurality of modules inthe electrical machine is determined based in part on one or moreoperating parameters; wherein the plurality of modules are capable ofbeing independently controlled, and wherein the plurality of modules arecapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, and atleast one performance parameter during operation; and wherein theelectrical machine is configured to fit into a housing and that can beretrofitted into a conventional vehicle by replacing the differential.

Example 5B An electrical machine comprising: a plurality of stators; aplurality of modules comprising at least one electromagnetic coil and atleast one switch and being attached to at least one of the plurality ofstators; a plurality of rotors with a plurality of magnets attached toat least one of the plurality of rotors, the plurality of rotors areable to move independently to one another to produce a differentialoutput that permits the electric machine to output at least tworotational outputs to corresponding shafts, wherein the at least tworotational outputs are able to move the shafts at different rotationalvelocity's relative to one another, and the plurality of modules are inspaced relation to the plurality of the magnets; and the plurality ofrotors being in a rotational relationship with the plurality of stators;wherein the quantity and configuration of the plurality of modules inthe electrical machine is determined based in part on one or moreoperating parameters; wherein the plurality of modules are capable ofbeing independently controlled, and wherein the plurality of modules arecapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, and atleast one performance parameter during operation; and wherein theelectrical machine is configured to fit into a housing and that can belocated in substantially that same position where a differential wouldotherwise be located in a vehicle or other machine.

Example 6B An electrical machine comprising: at least one stator; atleast one module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to the at least one stator; at least one platter or rotorwith a plurality of magnets attached to the at least one platter orrotor, wherein the at least one module is in spaced relation to theplurality of the magnets; an integrated differential coupled to at leastone of the at least one platters or rotors, the at least one integrateddifferential permitting the at least one platter or rotor to output atleast two rotational outputs to corresponding shafts, wherein the atleast two rotational outputs are able to move the shafts at differentrotational velocities relative to one another, and the at least oneplatter or rotor being movement relationship with the at least onestator, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; wherein the at least one module is capable ofbeing independently controlled; and wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, or combinationsthereof.

Example 7B The electrical machine of one or more of the above Bexamples, wherein the at least one operating parameter during operationmay be selected from one or more of the following: maximum angularvelocity, average angular velocity, minimum angular velocity, maximumpower output, average power output, minimum power output, maximum inputvoltage, average input voltage, minimum input voltage, maximumgeneration voltage, average generation voltage, minimum generationvoltage, shape and frequency of generated voltage, peak input current,average input current, minimum input current, maximum generationcurrent, average generation current, minimum generation current, maximumtorque, average torque, minimum torque, torque smoothness, activationsequence, rate of acceleration, order of accuracy of hold angle,minimising the variation of angular velocity, rate of decelerationduring breaking, diameter of the shaft, maximum radius of the electricalmachine, maximum length of the electrical machine, maximum depth of theelectrical machine, maximum height of the machine, maximum slidedistance, minimum slide distance, maximum weight of the machine, minimumweight of the machine, maximum resistive power loss and unit redundancyand overall price.

Example 8B The electrical machine of one or more of the above Bexamples, wherein the at least one performance parameter duringoperation may be selected from one or more of the following: maximumangular velocity, maximum power output, deviation from output voltageduring generation, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave andaccuracy of generated frequency.

Example 9B The electrical machine of one or more of the above Bexamples, wherein the power to weight ratio of the electrical machine isat between 10 to 1, 15 to 3, 10 to 0.5, 9 to 4, 5 to 0.01, 3.4 to 6 or8.4 to 3.4 kilowatts per kilogram.

Example 10B The electrical machine of one or more of the above Bexamples, further comprising at least one sensor to detect absolute orrelative position of the at least one rotor; and at least one controlsystem which, in response to inputs from the one or more of thefollowing: the at least one sensor, at least one power command, at leastone mode command comprising one or more of the following: at least onedrive, generate, braking and hold command and at least one rotationaldirection command.

Example 11B The electrical machine of example 10B, wherein the at leastone control system is configured to be in a drive configuration or hasthe at least one drive mode command, the at least one control systemactivates at least one switch which energies one or more of the magneticcoils to attract and repel the magnets for the purpose of generatingmotion.

Example 12B The electrical machine of example 10B, wherein theelectrical machine is configured to be in a generation configuration orhas at least one mode command to generate power, the at least onecontrol system activates at least one switch which connects one or morecoils to the external power rails.

Example 13B The electrical machine of example 10B, wherein theelectrical machine is configured to be in a braking configuration or hasthe at least one mode command to brake, the at least one control systemactivates at least one switch which connects one or more of the magneticcoils terminals together to oppose motion.

Example 14B The electrical machine of example 10B, wherein theelectrical machine is configured to be in a holding configuration or hasthe at least one mode command to hold, the at least one control systemactivates at least one switch energises one or more of the magneticcoils to attract and repel magnets for the purpose of stopping motion.

Example 15B The electrical machine of one or more of the above Bexamples, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.

Example 16B The electrical machine of one or more of the above Bexamples, wherein the electrical machine has a power density of between100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000to 15,000, 10,000 to 20,000 or 10,000 to 30,000 kw/meter cubed.

Example 17B The electrical machine of one or more of the above Bexamples, wherein one or more of the at least one operating parameter,the at least one performance parameter or combinations thereof of theelectrical machine may be reconfigured in substantially real time.

Example 18B The electrical machine of one or more of the above Bexamples, wherein the at least one control system provides individualcontrol over at least 30%, 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% ofthe plurality of coils.

Example 19B The electrical machine of one or more of the above Bexamples, wherein the module coil activation sequence is computed duringmachine operation the order of modules activating being sequentiallybased on their geometric position in the module array.

Example 20B The electrical machine of one or more of the above Bexamples, wherein the module coil activation sequence is computed duringmachine operation, the order of modules activating being based uponsensor feedback.

Example 21B The electrical machine of one or more of the above Bexamples, wherein the module coil activation sequence is computed duringmachine operation and the order of the at least one modules activatingbeing determined by at least in part one or more sequence patterns.

Example 22B The electrical machine of one or more of the above examples,wherein the total number of the at least one electromagnetic coilspowered in the active sequence may vary during operation from the totalnumber of coils, to none.

Example 23B The electrical machine of one or more of the above Bexamples, wherein the control of the electrical machine is centralisedon at least one control module.

Example 24B The electrical machine of one or more of the above examples,wherein one or more modules may be individually removed, added, orreplaced during operation of the machine, without substantiallyaffecting the operational state of the machine.

Example 25B The electrical machine of one or more of the above Bexamples, wherein the at least one module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, wherein the at least oneoperating parameter during operation may be selected from one or more ofthe parameters listed in example 7B; at least one performance parameterduring operation, wherein the at least one performance parameter duringoperation may be selected from one or more of the parameter listed inexample 8B; or combinations thereof.

Example 26B The electrical machine of one or more of the above Bexamples, wherein the electrical machine is a compact direct driveelectric motor that generates sufficient or improved propulsion in awheeled vehicle and the electric motor and the differential can fit thesize of envelope of existing differentials in a conventional combustionengine driven vehicle.

Example 27B The electrical machine of one or more of the above Bexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient or improved propulsion of awheeled vehicle and the electric motor and the differential can beinstalled in line with a drive axial while providing adequate clearancefrom a road without substantial modification to an existing suspensionof the wheeled vehicle.

Example 28B The electrical machine of one or more of the above Bexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient propulsion of a wheeled vehicleand the electric motor and the differential can be installed in linewith one or more drive axels while providing adequate clearance from aroad without substantial modification to an existing suspension of thewheeled vehicle.

Example 29B The electrical machine of one or more of the above Bexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient propulsion of a wheeled vehicleand the electric motor and the differential can be installed in linewith one or more drive axels without lower, or substantially lowering,the clearance from a road and without substantial modification to anexisting suspension of the wheeled vehicle.

Example 1C An electrical machine comprising: at least one stator; atleast one module, wherein a substantial portion of the modules compriseat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; at least one rotorwith a plurality of magnets attached to the at least one rotor, whereinthe at least one module is in spaced relation to the plurality of themagnets; an integrated differential coupled to at least one of the atleast one rotors, the at least one integrated differential permittingthe at least one rotor to output at least two rotational outputs tocorresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocities relative toone another, and the at least one rotor being in a rotationalrelationship with the at least one stator; wherein the quantity andconfiguration of the substantial portion of the modules in theelectrical machine is determined based in part on one or more operatingparameters; wherein the substantial portion of modules are capable ofbeing independently controlled;

wherein the substantial portion of modules are capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, at least one performanceparameter during operation, and combinations thereof; and wherein theelectrical machine is configured to fit into a housing and that can beretrofitted into a conventional vehicle by replacing the differential.

Example 2C An electrical machine comprising: at least one stator; atleast one module, wherein a substantial portion of the modules compriseat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; at least one rotorwith a plurality of magnets attached to the at least one rotor, whereinthe at least one module is in spaced relation to the plurality of themagnets; an integrated differential coupled to at least one of the atleast one rotors, the at least one integrated differential permittingthe at least one rotor to output at least two rotational outputs tocorresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocities relative toone another, and the at least one rotor being in a rotationalrelationship with the at least one stator; wherein the quantity andconfiguration of the substantial portion of modules in the electricalmachine are determined based in part on one or more operatingparameters; wherein the substantial portion of the modules are capableof being independently controlled; wherein the substantial portion ofmodules are capable of being reconfigured based at least in part on oneor more of the following: at least one operating parameter duringoperation, at least one performance parameter during operation, andcombinations thereof; and wherein the electrical machine is configuredto fit into a housing and that can be located in substantially that sameposition where a differential would otherwise be located in a vehicle orother machine.

Example 3C An electrical machine comprising: a plurality of stators; aplurality of modules, wherein a substantial portion of the modulescomprise at least one electromagnetic coil and at least one switch andbeing attached to at least one of the plurality of stators; a pluralityof rotors with a plurality of magnets attached to at least one of theplurality of rotors, the plurality of rotors are able to moveindependently to one another to produce a differential output thatpermits the electric machine to output at least two rotational outputsto corresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocity's relative toone another, and the plurality of modules are in spaced relation to theplurality of the magnets; and the plurality of rotors being in arotational relationship with the plurality of stators; wherein thequantity and configuration of the substantial portion of the modules inthe electrical machine are determined based in part on one or moreoperating parameters; wherein the substantial portion of the modules arecapable of being independently controlled, and wherein the substantialportion of the modules are capable of being reconfigured based at leastin part on one or more of the following: at least one operatingparameter during operation, and at least one performance parameterduring operation; and wherein the electrical machine is configured tofit into a housing and that can be located in substantially that sameposition where a differential would otherwise be located in a vehicle orother machine.

Example 4C An electrical machine comprising: a plurality of stators; aplurality of modules, wherein a substantial portion of the modulescomprise at least one electromagnetic coil and at least one switch andbeing attached to at least one of the plurality of stators; a pluralityof rotors with a plurality of magnets attached to at least one of theplurality of rotors, the plurality of rotors are able to moveindependently to one another to produce a differential output thatpermits the electric machine to output at least two rotational outputsto corresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocity's relative toone another, and the plurality of modules are in spaced relation to theplurality of the magnets; and the plurality of rotors being in arotational relationship with the plurality of stators; wherein thequantity and configuration of the substantial portion of the modules inthe electrical machine are determined based in part on one or moreoperating parameters; wherein the substantial portion of the modules arecapable of being independently controlled, and wherein the substantialportion of the modules are capable of being reconfigured based at leastin part on one or more of the following: at least one operatingparameter during operation, and at least one performance parameterduring operation; and wherein the electrical machine is configured tofit into a housing and that can be retrofitted into a conventionalvehicle by replacing the differential.

Example 5C An electrical machine comprising: a plurality of stators; aplurality of modules, wherein a substantial portion of the modulescomprise at least one electromagnetic coil and at least one switch andbeing attached to at least one of the plurality of stators; a pluralityof rotors with a plurality of magnets attached to at least one of theplurality of rotors, the plurality of rotors are able to moveindependently to one another to produce a differential output thatpermits the electric machine to output at least two rotational outputsto corresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocity's relative toone another, and the plurality of modules are in spaced relation to theplurality of the magnets; and the plurality of rotors being in arotational relationship with the plurality of stators; wherein thequantity and configuration of the substantial portion of the modules inthe electrical machine is determined based in part on one or moreoperating parameters; wherein the substantial portion of the modules arecapable of being independently controlled, and wherein the substantialportion of the modules are capable of being reconfigured based at leastin part on one or more of the following: at least one operatingparameter during operation, and at least one performance parameterduring operation; and wherein the electrical machine is configured tofit into a housing and that can be located in substantially that sameposition where a differential would otherwise be located in a vehicle orother machine.

Example 6C An electrical machine comprising: at least one stator; atleast one module, wherein a substantial portion of the modules compriseat least one electromagnetic coil and at least one switch, the at leastone module being attached to the at least one stator; at least oneplatter or rotor with a plurality of magnets attached to the at leastone platter or rotor, wherein the at least one module is in spacedrelation to the plurality of the magnets; an integrated differentialcoupled to at least one of the at least one platters or rotors, the atleast one integrated differential permitting the at least one platter orrotor to output at least two rotational outputs to corresponding shafts,wherein the at least two rotational outputs are able to move the shaftsat different rotational velocities relative to one another, and the atleast one platter or rotor being movement relationship with the at leastone stator,

-   wherein the quantity and configuration of the substantial portion of    the modules in the electrical machine are determined based in part    on one or more operating parameters; wherein the substantial portion    of the modules are capable of being independently controlled; and    wherein the substantial portion of the modules are capable of being    reconfigured based at least in part on one or more of the following:    at least one operating parameter during operation, at least one    performance parameter during operation, or combinations thereof.

Example 7C The electrical machine of one or more of the above Cexamples, wherein the at least one operating parameter during operationmay be selected from one or more of the following: maximum angularvelocity, average angular velocity, minimum angular velocity, maximumpower output, average power output, minimum power output, maximum inputvoltage, average input voltage, minimum input voltage, maximumgeneration voltage, average generation voltage, minimum generationvoltage, shape and frequency of generated voltage, peak input current,average input current, minimum input current, maximum generationcurrent, average generation current, minimum generation current, maximumtorque, average torque, minimum torque, torque smoothness, activationsequence, rate of acceleration, order of accuracy of hold angle,minimising the variation of angular velocity, rate of decelerationduring breaking, diameter of the shaft, maximum radius of the electricalmachine, maximum length of the electrical machine, maximum depth of theelectrical machine, maximum height of the machine, maximum slidedistance, minimum slide distance, maximum weight of the machine, minimumweight of the machine, maximum resistive power loss, and unit redundancyand overall price.

Example 8C The electrical machine of one or more of the above Cexamples, wherein the at least one performance parameter duringoperation may be selected from one or more of the following: maximumangular velocity, maximum power output, deviation from output voltageduring generation, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave, andaccuracy of generated frequency.

Example 9C The electrical machine of one or more of the above Cexamples, wherein the power to weight ratio of the electrical machine isat between 10 to 1, 15 to 3, 10 to 0.5, 9 to 4, 5 to 0.01, 3.4 to 6 or8.4 to 3.4 kilowatts per kilogram.

Example 10C The electrical machine of one or more of the above Cexamples, further comprising at least one sensor to detect absolute orrelative position of the at least one rotor; and at least one controlsystem which, in response to inputs from the one or more of thefollowing: the at least one sensor, at least one power command, at leastone mode command comprising one or more of the following: at least onedrive, generate, braking and hold command and at least one rotationaldirection command.

Example 11C The electrical machine of example 10C, wherein the at leastone control system is configured to be in a drive configuration or hasthe at least one drive mode command, the at least one control systemactivates at least one switch which energies one or more of the magneticcoils to attract and repel the magnets for the purpose of generatingmotion.

Example 12C The electrical machine of example 10C, wherein theelectrical machine is configured to be in a generation configuration orhas at least one mode command to generate power, the at least onecontrol system activates at least one switch which connects one or morecoils to the external power rails.

Example 13C The electrical machine of example 10C, wherein theelectrical machine is configured to be in a braking configuration or hasthe at least one mode command to brake, the at least one control systemactivates at least one switch which connects one or more of the magneticcoils terminals together to oppose motion.

Example 14C The electrical machine of example 10C, wherein theelectrical machine is configured to be in a holding configuration or hasthe at least one mode command to hold, the at least one control systemactivates at least one switch energises one or more of the magneticcoils to attract and repel magnets for the purpose of stopping motion.

Example 15C The electrical machine of one or more of the above Cexamples, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.

Example 16C The electrical machine of one or more of the above Cexamples, wherein the electrical machine has a power density of between100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000to 15,000, 10,000 to 30,000 or 10,000 to 20,000 kw/meter cubed.

Example 17C The electrical machine of one or more of the above Cexamples, wherein one or more of the at least one operating parameter,the at least one performance parameter or combinations thereof of theelectrical machine may be reconfigured in substantially real time.

Example 18C The electrical machine of one or more of the above Cexamples, wherein the at least one control system provides individualcontrol over at least 30%, 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% ofthe plurality of coils.

Example 19C The electrical machine of one or more of the above Cexamples, wherein the module coil activation sequence is computed duringmachine operation the order of modules activating being sequentiallybased on their geometric position in the module array.

Example 20C The electrical machine of one or more of the above Cexamples, wherein the module coil activation sequence is computed duringmachine operation, the order of modules activating being based uponsensor feedback.

Example 21C The electrical machine of one or more of the above Cexamples, wherein the module coil activation sequence is computed duringmachine operation and the order of the at least one modules activatingbeing determined by at least in part one or more sequence patterns.

Example 22C The electrical machine of one or more of the above Cexamples, wherein the total number of the at least one electromagneticcoils powered in the active sequence may vary during operation from thetotal number of coils, to none.

Example 23C The electrical machine of one or more of the above Cexamples, wherein the control of the electrical machine is centralisedon at least one control module.

Example 24C The electrical machine of one or more of the above Cexamples, wherein one or more modules may be individually removed,added, or replaced during operation of the machine, withoutsubstantially affecting the operational state of the machine.

Example 25C The electrical machine of one or more of the above Cexamples, wherein the substantial portion of the modules are capable ofbeing reconfigured based at least in part on one or more of thefollowing: at least one operating parameter during operation, whereinthe at least one operating parameter during operation may be selectedfrom one or more of the parameters listed in example 2C; at least oneperformance parameter during operation, wherein the at least oneperformance parameter during operation may be selected from one or moreof the parameter listed in example 3C; or combinations thereof.

Example 26C The electrical machine of one or more of the above Cexamples, wherein the electrical machine is a compact direct driveelectric motor that generates sufficient or improved propulsion in awheeled vehicle and the electric motor and the differential can fit thesize of envelope of existing differentials in a conventional combustionengine driven vehicle.

Example 27C The electrical machine of one or more of the above Cexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient or improved propulsion of awheeled vehicle and the electric motor and the differential can beinstalled in line with a drive axial while providing adequate clearancefrom a road without substantial modification to an existing suspensionof the wheeled vehicle.

Example 28C The electrical machine of one or more of the above Cexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient propulsion of a wheeled vehicleand the electric motor and the differential can be installed in linewith one or more drive axels while providing adequate clearance from aroad without substantial modification to an existing suspension of thewheeled vehicle.

Example 29C The electrical machine of one or more of the above Cexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient propulsion of a wheeled vehicleand the electric motor and the differential can be installed in linewith one or more drive axels without lower, or substantially lowering,the clearance from a road and without substantial modification to anexisting suspension of the wheeled vehicle.

Example ID An electrical machine comprising: at least one stator; atleast one module, each module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one rotor with a plurality of magnetsattached to the at least one rotor, wherein the at least one module isin spaced relation to the plurality of the magnets; an integrateddifferential coupled to at least one of the at least one rotors, the atleast one integrated differential permitting the at least one rotor tooutput at least two rotational outputs to corresponding shafts, whereinthe at least two rotational outputs are able to move the shafts atdifferent rotational velocities relative to one another, and the atleast one rotor being in a rotational relationship with the at least onestator; wherein the quantity and configuration of each module in theelectrical machine is determined based in part on one or more operatingparameters; wherein each module is capable of being independentlycontrolled;

wherein each module is capable of being reconfigured based at least inpart on one or more of the following: at least one operating parameterduring operation, at least one performance parameter during operation,and combinations thereof; and wherein the electrical machine isconfigured to fit into a housing and that can be retrofitted into aconventional vehicle by replacing the differential.

Example 21D An electrical machine comprising: at least one stator; atleast one module, each module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one rotor with a plurality of magnetsattached to the at least one rotor, wherein the at least one module isin spaced relation to the plurality of the magnets; an integrateddifferential coupled to at least one of the at least one rotors, the atleast one integrated differential permitting the at least one rotor tooutput at least two rotational outputs to corresponding shafts, whereinthe at least two rotational outputs are able to move the shafts atdifferent rotational velocities relative to one another, and the atleast one rotor being in a rotational relationship with the at least onestator; wherein the quantity and configuration of each one module in theelectrical machine is determined based in part on one or more operatingparameters; wherein each module is capable of being independentlycontrolled; wherein each module is capable of being reconfigured basedat least in part on one or more of the following: at least one operatingparameter during operation, at least one performance parameter duringoperation, and combinations thereof; and wherein the electrical machineis configured to fit into a housing and that can be located insubstantially that same position where a differential would otherwise belocated in a vehicle or other machine.

Example 3D An electrical machine comprising: a plurality of stators; aplurality of modules, each module comprising at least oneelectromagnetic coil and at least one switch and being attached to atleast one of the plurality of stators; a plurality of rotors with aplurality of magnets attached to at least one of the plurality ofrotors, the plurality of rotors are able to move independently to oneanother to produce a differential output that permits the electricmachine to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocity's relative to one another, andthe plurality of modules are in spaced relation to the plurality of themagnets; and the plurality of rotors being in a rotational relationshipwith the plurality of stators; wherein the quantity and configuration ofeach module in the electrical machine is determined based in part on oneor more operating parameters; wherein each module is capable of beingindependently controlled, and wherein each module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, and at least oneperformance parameter during operation; and wherein the electricalmachine is configured to fit into a housing and that can be located insubstantially that same position where a differential would otherwise belocated in a vehicle or other machine.

Example 4D An electrical machine comprising: a plurality of stators; aplurality of modules, each module comprising at least oneelectromagnetic coil and at least one switch and being attached to atleast one of the plurality of stators; a plurality of rotors with aplurality of magnets attached to at least one of the plurality ofrotors, the plurality of rotors are able to move independently to oneanother to produce a differential output that permits the electricmachine to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocity's relative to one another, andthe plurality of modules are in spaced relation to the plurality of themagnets; and the plurality of rotors being in a rotational relationshipwith the plurality of stators; wherein the quantity and configuration ofeach module in the electrical machine is determined based in part on oneor more operating parameters; wherein each module is capable of beingindependently controlled, and wherein each module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, and at least oneperformance parameter during operation; and wherein the electricalmachine is configured to fit into a housing and that can be retrofittedinto a conventional vehicle by replacing the differential.

Example 5D An electrical machine comprising: a plurality of stators; aplurality of modules, each module comprising at least oneelectromagnetic coil and at least one switch and being attached to atleast one of the plurality of stators; a plurality of rotors with aplurality of magnets attached to at least one of the plurality ofrotors, the plurality of rotors are able to move independently to oneanother to produce a differential output that permits the electricmachine to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocity's relative to one another, andthe plurality of modules are in spaced relation to the plurality of themagnets; and the plurality of rotors being in a rotational relationshipwith the plurality of stators; wherein the quantity and configuration ofeach module in the electrical machine is determined based in part on oneor more operating parameters; wherein each module is capable of beingindependently controlled, and wherein each module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, and at least oneperformance parameter during operation; and wherein the electricalmachine is configured to fit into a housing and that can be located insubstantially that same position where a differential would otherwise belocated in a vehicle or other machine.

Example 6D An electrical machine comprising: at least one stator; atleast one module, each module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnets attached to the at least one platter or rotor, wherein the atleast one module is in spaced relation to the plurality of the magnets;an integrated differential coupled to at least one of the at least oneplatters or rotors, the at least one integrated differential permittingthe at least one platter or rotor to output at least two rotationaloutputs to corresponding shafts, wherein the at least two rotationaloutputs are able to move the shafts at different rotational velocitiesrelative to one another, and the at least one platter or rotor beingmovement relationship with the at least one stator, wherein the quantityand configuration of each module in the electrical machine is determinedbased in part on one or more operating parameters; wherein each moduleis capable of being independently controlled; and wherein each module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, or combinationsthereof.

Example 7D The electrical machine of one or more of the above Dexamples, wherein the at least one operating parameter during operationmay be selected from one or more of the following: maximum angularvelocity, average angular velocity, minimum angular velocity, maximumpower output, average power output, minimum power output, maximum inputvoltage, average input voltage, minimum input voltage, maximumgeneration voltage, average generation voltage, minimum generationvoltage, shape and frequency of generated voltage, peak input current,average input current, minimum input current, maximum generationcurrent, average generation current, minimum generation current, maximumtorque, average torque, minimum torque, torque smoothness, activationsequence, rate of acceleration, order of accuracy of hold angle,minimising the variation of angular velocity, rate of decelerationduring breaking, diameter of the shaft, maximum radius of the electricalmachine, maximum length of the electrical machine, maximum depth of theelectrical machine, maximum height of the machine, maximum slidedistance, minimum slide distance, maximum weight of the machine, minimumweight of the machine, maximum resistive power loss, and unit redundancyand overall price.

Example 8D The electrical machine of one or more of the above Dexamples, wherein the at least one performance parameter duringoperation may be selected from one or more of the following: maximumangular velocity, maximum power output, deviation from output voltageduring generation, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave, andaccuracy of generated frequency.

Example 9D The electrical machine of one or more of the above examples,wherein the power to weight ratio of the electrical machine is atbetween 10 to 1, 15 to 3, 10 to 0.5, 9 to 4, 5 to 0.01, 3.4 to 6 or 8.4to 3.4 kilowatts per kilogram.

Example 10D The electrical machine of one or more of the above Dexamples, further comprising at least one sensor to detect absolute orrelative position of the at least one rotor; and at least one controlsystem which, in response to inputs from the one or more of thefollowing: the at least one sensor, at least one power command, at leastone mode command comprising one or more of the following: at least onedrive, generate, braking and hold command, and at least one rotationaldirection command.

Example 11D The electrical machine of example 10D, wherein the at leastone control system is configured to be in a drive configuration or hasthe at least one drive mode command, the at least one control systemactivates at least one switch which energies one or more of the magneticcoils to attract and repel the magnets for the purpose of generatingmotion.

Example 12D The electrical machine of example 10D, wherein theelectrical machine is configured to be in a generation configuration orhas at least one mode command to generate power, the at least onecontrol system activates at least one switch which connects one or morecoils to the external power rails.

Example 13D The electrical machine of example 10D, wherein theelectrical machine is configured to be in a braking configuration or hasthe at least one mode command to brake, the at least one control systemactivates at least one switch which connects one or more of the magneticcoils terminals together to oppose motion.

Example 14D The electrical machine of example 10D, wherein theelectrical machine is configured to be in a holding configuration or hasthe at least one mode command to hold, the at least one control systemactivates at least one switch energises one or more of the magneticcoils to attract and repel magnets for the purpose of stopping motion.

Example 15D The electrical machine of one or more of the above Dexamples, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.

Example 16D The electrical machine of one or more of the above Dexamples, wherein the electrical machine has a power density of between100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000to 15,000, 10,000 to 30,000 or 10,000 to 20,000 kw/meter cubed.

Example 17D The electrical machine of one or more of the above Dexamples, wherein one or more of the at least one operating parameter,the at least one performance parameter or combinations thereof of theelectrical machine may be reconfigured in substantially real time.

Example 18D The electrical machine of one or more of the above Dexamples, wherein the at least one control system provides individualcontrol over at least 30%, 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% ofthe plurality of coils.

Example 19D The electrical machine of one or more of the above Dexamples, wherein the module coil activation sequence is computed duringmachine operation the order of modules activating being sequentiallybased on their geometric position in the module array.

Example 20D The electrical machine of one or more of the above Dexamples, wherein the module coil activation sequence is computed duringmachine operation, the order of modules activating being based uponsensor feedback.

Example 21D The electrical machine of one or more of the above Dexamples, wherein the module coil activation sequence is computed duringmachine operation and the order of the at least one modules activatingbeing determined by at least in part one or more sequence patterns.

Example 22D The electrical machine of one or more of the above Dexamples, wherein the total number of the at least one electromagneticcoils powered in the active sequence may vary during operation from thetotal number of coils, to none.

Example 23D The electrical machine of one or more of the above Dexamples, wherein the control of the electrical machine is centralisedon at least one control module.

Example 24D The electrical machine of one or more of the above Dexamples, wherein one or more modules may be individually removed,added, or replaced during operation of the machine, withoutsubstantially affecting the operational state of the machine.

Example 25D The electrical machine of one or more of the above Dexamples, wherein each module is capable of being reconfigured based atleast in part on one or more of the following: at least one operatingparameter during operation, wherein the at least one operating parameterduring operation may be selected from one or more of the parameterslisted in example 7D; at least one performance parameter duringoperation, wherein the at least one performance parameter duringoperation may be selected from one or more of the parameter listed inexample 8D; or combinations thereof.

Example 26D The electrical machine of one or more of the above Dexamples, wherein the electrical machine is a compact direct driveelectric motor that generates sufficient or improved propulsion in awheeled vehicle and the electric motor and the differential can fit thesize of envelope of existing differentials in a conventional combustionengine driven vehicle.

Example 27D The electrical machine of one or more of the above Dexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient or improved propulsion of awheeled vehicle and the electric motor and the differential can beinstalled in line with a drive axial while providing adequate clearancefrom a road without substantial modification to an existing suspensionof the wheeled vehicle.

Example 28D The electrical machine of one or more of the above Dexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient propulsion of a wheeled vehicleand the electric motor and the differential can be installed in linewith one or more drive axels while providing adequate clearance from aroad without substantial modification to an existing suspension of thewheeled vehicle.

Example 29D The electrical machine of one or more of the above Dexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient propulsion of a wheeled vehicleand the electric motor and the differential can be installed in linewith one or more drive axels without lower, or substantially lowering,the clearance from a road and without substantial modification to anexisting suspension of the wheeled vehicle.

Example 1E An electrical machine comprising: at least one stator; atleast one module comprising at least one electromagnetic coil and atleast one switch, the at least one module being attached to the at leastone stator; at least one rotor with a plurality of magnets attached tothe at least one rotor, wherein the at least one module is in spacedrelation to the plurality of the magnets; an integrated differentialcoupled to at least one of the at least one rotors, the at least oneintegrated differential permitting the at least one rotor to output atleast two rotational outputs to corresponding shafts, wherein the atleast two rotational outputs are able to move the shafts at differentrotational velocities relative to one another, and the at least onerotor being in a rotational relationship with the at least one stator;

wherein the quantity and configuration of a substantial portion of themodules in the electrical machine are determined based in part on one ormore operating parameters; wherein a substantial portion of the modulesare capable of being independently controlled;

wherein a substantial portion of the modules is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, at least one performanceparameter during operation, and combinations thereof; and

wherein the electrical machine is configured to fit into a housing andthat can be retrofitted into a conventional vehicle by replacing thedifferential.

Example 2E An electrical machine comprising: at least one stator; atleast one module, each module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one rotor with a plurality of magnetsattached to the at least one rotor, wherein the at least one module isin spaced relation to the plurality of the magnets; an integrateddifferential coupled to at least one of the at least one rotors, the atleast one integrated differential permitting the at least one rotor tooutput at least two rotational outputs to corresponding shafts,

wherein the at least two rotational outputs are able to move the shaftsat different rotational velocities relative to one another, and the atleast one rotor being in a rotational relationship with the at least onestator;

wherein the quantity and configuration of each one module in theelectrical machine is determined based in part on one or more operatingparameters; wherein each module is capable of being independentlycontrolled;

wherein each module is capable of being reconfigured based at least inpart on one or more of the following: at least one operating parameterduring operation, at least one performance parameter during operation,and combinations thereof; and

wherein the electrical machine is configured to fit into a housing andthat can be located in substantially that same position where adifferential would otherwise be located in a vehicle or other machine.

Example 3E An electrical machine comprising: a plurality of stators; aplurality of modules, wherein a substantial portion of the modulescomprise at least one electromagnetic coil and at least one switch andare attached to at least one of the plurality of stators; a plurality ofrotors with a plurality of magnets attached to at least one of theplurality of rotors, the plurality of rotors are able to moveindependently to one another to produce a differential output thatpermits the electric machine to output at least two rotational outputsto corresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocity's relative toone another, and the plurality of modules are in spaced relation to theplurality of the magnets; and the plurality of rotors being in arotational relationship with the plurality of stators;

wherein the quantity and configuration of the substantial portion of themodules in the electrical machine are determined based in part on one ormore operating parameters;

wherein the substantial portion of the modules are capable of beingindependently controlled, and wherein the substantial portion of themodules are capable of being reconfigured based at least in part on oneor more of the following: at least one operating parameter duringoperation, and at least one performance parameter during operation; and

wherein the electrical machine is configured to fit into a housing andthat can be located in substantially that same position where adifferential would otherwise be located in a vehicle or other machine.

Example 4E An electrical machine comprising: a plurality of stators; aplurality of modules, each module comprising at least oneelectromagnetic coil and at least one switch and being attached to atleast one of the plurality of stators; a plurality of rotors with aplurality of magnets attached to at least one of the plurality ofrotors, the plurality of rotors are able to move independently to oneanother to produce a differential output that permits the electricmachine to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocity's relative to one another, andthe plurality of modules are in spaced relation to the plurality of themagnets; and the plurality of rotors being in a rotational relationshipwith the plurality of stators;

wherein the quantity and configuration of each module in the electricalmachine is determined based in part on one or more operating parameters;

wherein each module is capable of being independently controlled, and

wherein each module is capable of being reconfigured based at least inpart on one or more of the following: at least one operating parameterduring operation, and at least one performance parameter duringoperation; and wherein the electrical machine is configured to fit intoa housing and that can be retrofitted into a conventional vehicle byreplacing the differential.

Example 5E An electrical machine comprising: a plurality of stators; aplurality of modules, each module comprising at least oneelectromagnetic coil and at least one switch and being attached to atleast one of the plurality of stators; a plurality of rotors with aplurality of magnets attached to at least one of the plurality ofrotors, the plurality of rotors are able to move independently to oneanother to produce a differential output that permits the electricmachine to output at least two rotational outputs to correspondingshafts, wherein the at least two rotational outputs are able to move theshafts at different rotational velocity's relative to one another, andthe plurality of modules are in spaced relation to the plurality of themagnets; and the plurality of rotors being in a rotational relationshipwith the plurality of stators;

wherein the quantity and configuration of each module in the electricalmachine is determined based in part on one or more operating parameters;

wherein each module is capable of being independently controlled, and

wherein each module is capable of being reconfigured based at least inpart on one or more of the following: at least one operating parameterduring operation, and at least one performance parameter duringoperation; and wherein the electrical machine is configured to fit intoa housing and that can be located in substantially that same positionwhere a differential would otherwise be located in a vehicle or othermachine.

Example 6E An electrical machine comprising: at least one stator; atleast one module, each module comprising at least one electromagneticcoil and at least one switch, the at least one module being attached tothe at least one stator; at least one platter or rotor with a pluralityof magnets attached to the at least one platter or rotor, wherein the atleast one module is in spaced relation to the plurality of the magnets;an integrated differential coupled to at least one of the at least oneplatters or rotors, the at least one integrated differential permittingthe at least one platter or rotor to output at least two rotationaloutputs to corresponding shafts,

wherein the at least two rotational outputs are able to move the shaftsat different rotational velocities relative to one another, and the atleast one platter or rotor being movement relationship with the at leastone stator,

wherein the quantity and configuration of each module in the electricalmachine is determined based in part on one or more operating parameters;wherein each module is capable of being independently controlled; and

wherein each module is capable of being reconfigured based at least inpart on one or more of the following: at least one operating parameterduring operation, at least one performance parameter during operation,or combinations thereof.

Example 7E The electrical machine of one or more of the above Eexamples, wherein the at least one operating parameter during operationmay be selected from one or more of the following: maximum angularvelocity, average angular velocity, minimum angular velocity, maximumpower output, average power output, minimum power output, maximum inputvoltage, average input voltage, minimum input voltage, maximumgeneration voltage, average generation voltage, minimum generationvoltage, shape and frequency of generated voltage, peak input current,average input current, minimum input current, maximum generationcurrent, average generation current, minimum generation current, maximumtorque, average torque, minimum torque, torque smoothness, activationsequence, rate of acceleration, order of accuracy of hold angle,minimising the variation of angular velocity, rate of decelerationduring breaking, diameter of the shaft, maximum radius of the electricalmachine, maximum length of the electrical machine, maximum depth of theelectrical machine, maximum height of the machine, maximum slidedistance, minimum slide distance, maximum weight of the machine, minimumweight of the machine, maximum resistive power loss, and unit redundancyand overall price.

Example 8E The electrical machine of one or more of the above Eexamples, wherein the at least one performance parameter duringoperation may be selected from one or more of the following: maximumangular velocity, maximum power output, deviation from output voltageduring generation, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimising thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimising resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave andaccuracy of generated frequency.

Example 9E The electrical machine of one or more of the above Eexamples, wherein the power to weight ratio of the electrical machine isat between 10 to 1, 15 to 3, 10 to 0.5, 9 to 4, 5 to 0.01, 3.4 to 6 or8.4 to 3.4 kilowatts per kilogram.

Example 10E The electrical machine of one or more of the above Eexamples, further comprising at least one sensor to detect absolute orrelative position of the at least one rotor; and at least one controlsystem which, in response to inputs from the one or more of thefollowing: the at least one sensor, at least one power command, at leastone mode command comprising one or more of the following: at least onedrive, generate, braking and hold command and at least one rotationaldirection command.

Example 11E The electrical machine of example 10E, wherein the at leastone control system is configured to be in a drive configuration or hasthe at least one drive mode command, the at least one control systemactivates at least one switch which energies one or more of the magneticcoils to attract and repel the magnets for the purpose of generatingmotion.

Example 12E The electrical machine of example 10E, wherein theelectrical machine is configured to be in a generation configuration orhas at least one mode command to generate power, the at least onecontrol system activates at least one switch which connects one or morecoils to the external power rails.

Example 13E The electrical machine of example 10E, wherein theelectrical machine is configured to be in a braking configuration or hasthe at least one mode command to brake, the at least one control systemactivates at least one switch which connects one or more of the magneticcoils terminals together to oppose motion.

Example 14E The electrical machine of example 10E, wherein theelectrical machine is configured to be in a holding configuration or hasthe at least one mode command to hold, the at least one control systemactivates at least one switch energises one or more of the magneticcoils to attract and repel magnets for the purpose of stopping motion.

Example 15E The electrical machine of one or more of the above Eexamples, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.

Example 16E The electrical machine of one or more of the above Eexamples, wherein the electrical machine has a power density of between100 to 20,000, 100 to 200, 100 to 500, 250 to 500, 500 to 1000, 500 to2000, 1000 to 10,000, 1000 to 5000, 2000 to 5000, 5000 to 10,000, 5000to 15,000, 10,000 to 30,000 or 10,000 to 20,000 kw/meter cubed.

Example 17E The electrical machine of one or more of the above Eexamples, wherein one or more of the at least one operating parameter,the at least one performance parameter or combinations thereof of theelectrical machine may be reconfigured in substantially real time.

Example 18E The electrical machine of one or more of the above Eexamples, wherein the at least one control system provides individualcontrol over at least 30%, 40%, 50%, 60%, 70% 80%, 90%, 95% or 100% ofthe plurality of coils.

Example 19E The electrical machine of one or more of the above Eexamples, wherein the module coil activation sequence is computed duringmachine operation the order of modules activating being sequentiallybased on their geometric position in the module array.

Example 20E The electrical machine of one or more of the above Eexamples, wherein the module coil activation sequence is computed duringmachine operation, the order of modules activating being based uponsensor feedback.

Example 21E The electrical machine of one or more of the above Eexamples, wherein the module coil activation sequence is computed duringmachine operation and the order of the at least one modules activatingbeing determined by at least in part one or more sequence patterns.

Example 22E The electrical machine of one or more of the above Eexamples, wherein the total number of the at least one electromagneticcoils powered in the active sequence may vary during operation from thetotal number of coils, to none.

Example 23E The electrical machine of one or more of the above Eexamples, wherein the control of the electrical machine is centralisedon at least one control module.

Example 24E The electrical machine of one or more of the above Eexamples, wherein one or more modules may be individually removed,added, or replaced during operation of the machine, withoutsubstantially affecting the operational state of the machine.

Example 25E The electrical machine of one or more of the above Eexamples, wherein the substantial portion of the modules is all of themodules contained in the electrical machine.

Example 26E The electrical machine of one or more of the above Eexamples, wherein the electrical machine is a compact direct driveelectric motor that generates sufficient or improved propulsion in awheeled vehicle and the electric motor and the differential can fit thesize of envelope of existing differentials in a conventional combustionengine driven vehicle.

Example 27E The electrical machine of one or more of the above Eexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient or improved propulsion of awheeled vehicle and the electric motor and the differential can beinstalled in line with a drive axial while providing adequate clearancefrom a road without substantial modification to an existing suspensionof the wheeled vehicle.

Example 28E The electrical machine of one or more of the above Eexamples, wherein the electrical machine is a compact direct driveelectric motor that generate sufficient propulsion of a wheeled vehicleand the electric motor and the differential can be installed in linewith one or more drive axels while providing adequate clearance from aroad without substantial modification to an existing suspension of thewheeled vehicle.

Example 29E The electrical machine of one or more of the above Eexamples, wherein the electrical machine is a direct drive electricmotor that generate sufficient propulsion of a wheeled vehicle and theelectric motor and the differential are be installed in line with one ormore drive axels without lower, or substantially lowering, the clearancefrom a road and without substantial modification to an existingsuspension of the wheeled vehicle.

Example 30E.1 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is made bywrapping one or more conductor materials around a temporary fixturewhich is then removed.

Example 30E.2 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil comprises theone or more conductor materials wrapped around a bobbin.

Example 30E.3 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil comprises theone or more conductor materials wrapped around a core.

Example 31E.1 The electrical machine of examples 30E.1, 30E.2 and 30E.3,wherein the one or more conductor materials of the at least oneelectromagnetic coil have a circular or a partially circular crosssection.

Example 31E.2 The electrical machine of examples 30E.1, 30E.2 and 30E.3,wherein the one or more conductor materials of the at least oneelectromagnetic coil have a rectangular or a partially rectangular crosssection.

Example 31E.3 The electrical machine of examples 30E.1, 30E.2 and 30E.3,wherein the one or more conductor materials of the at least oneelectromagnetic coil have a rectangular or a partially rectangular crosssection bent along the long axis, This creates what is commonly known asan edge wound coil.

Example 31E.4 The electrical machine of examples 30E.1, 30E.2 and 30E.3,wherein the one or more conductor materials of the at least oneelectromagnetic coil have an arbitrarily shaped cross section.

Example 31E.5 The electrical machine of examples 30E.1, 30E.2 and 30E.3,wherein the one or more conductor materials of the at least oneelectromagnetic coil have a combination of one or more of the crosssections described in examples 31E.1, 31E.2, 31E.3 and 31E.4.

Example 31E. 6 The electrical machine of examples 30E.1, 30E.2 and30E.3, wherein the one or more conductor materials of the at least oneelectromagnetic coil is foil.

Example 32E.1 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is of acylindrical or a substantially cylindrical shape.

Example 32E.2 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is of arectangular or a substantially rectangular prism shape.

Example 32E.3 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is of atrapezoidal or a substantially trapezoidal prism shape.

Example 32E.4 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is of a oval ora substantially oval prism shape.

Example 33E.1 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil surrounds orpartially surrounds a cylindrical or a substantially cylindrical core.

Example 33E.2 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil surrounds orpartially surrounds a rectangular or a substantially rectangular prismcore.

Example 33E.3 The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil surrounds orpartially surrounds a trapezoidal or a substantially trapezoidal prismcore.

Example 34E.1 The electrical machine of one or more of the above Eexample, wherein along the at least one electromagnetic coil there is aarea of reduced cross section that is capable of fusing in an opencircuit or a partially open circuit state in the event of an amount ofcurrent that is beyond a predetermined amount of current.

Example 34E.2 The electrical machine of one or more of the above Eexample, wherein along the at least one electromagnetic coil there areat least two, three or four areas of reduced cross section that arecapable of fusing in an open circuit or a partially open circuit statein the event of an amount of current that is beyond a predeterminedamount of current.

Example 34E.3 The electrical machine of one or more of the above Eexample, wherein along the at least one electromagnetic coil there areat least one, two or three areas of reduced cross section per coilwinding that are capable of fusing in an open circuit or a partiallyopen circuit state in the event of an amount of current that is beyond apredetermined amount of current.

Example 35E.1 The electrical machine of one or more of the above Eexamples, wherein the one or more conductor materials is composed ofcopper or a copper alloy.

Example 35E.2 The electrical machine of one or more of the above Eexamples, wherein the one or more conductor materials is composed ofaluminium or an aluminium alloy.

Example 35E.3 The electrical machine of one or more of the above Eexamples, wherein the one or more conductor materials is composed ofgraphine, a graphine hybrid or another carbon based conductor.

Example 35E.4 The electrical machine of one or more of the above Eexamples, wherein the one or more conductor materials is composed of asuitably conductive material.

Example 36E.1 The electrical machine of one or more of the above Eexamples, wherein the one or more conductor materials is directly cooledby the flow of a suitable coolant directly over or over a layer ofelectrically insulating material.

Example 36E,2 The electrical machine of one or more of the above Eexamples, wherein the one or more conductor materials is within closeproximity of a thermally conductive material that is capable ofdissipating heat to a nearby coolant channel.

Example 36E.3 The electrical machine of one or more of the above Eexamples, wherein the one or more conductor materials is within closeproximity of the thermally conductive material is capable of conductingheat to a surface where the heat is at least in part removed byconvection and thermal radiation.

Example 37E The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is placed arounda core.

Example 38E.1 The electrical machine of example 37E, wherein the core ismade of laminated electrical steel.

Example 38E.2 The electrical machine of example 37E, wherein the core ismade of layers of amorphous metal.

Example 38E.3 The electrical machine of example 37E, wherein the core ismade of powdered metals.

Example 38E.4 The electrical machine of example 37E, wherein the core ismade of a material with suitable magnetic permeability.

Example 38E.5 The electrical machine of example 37E, wherein the core ismade of a magnetic permeable material.

Example 39E The electrical machine of one or more of the above Eexamples, wherein the at least one stator is a substantial portion ofthe stators contained in the electrical machine.

Example 40E The electrical machine of one or more of the above Eexamples, wherein the at least one stator is all of the statorscontained in the electrical machine.

Example 41E The electrical machine of one or more of the above Eexamples, wherein the at least one module is a substantial portion ofthe modules contained in the electrical machine.

Example 42E The electrical machine of one or more of the above Eexamples, wherein the at least one module is all of the modulescontained in the electrical machine.

Example 43E The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is a substantialportion of the electromagnetic coils contained in the electricalmachine.

Example 44E The electrical machine of one or more of the above Eexamples, wherein the at least one electromagnetic coil is all of theelectromagnetic coil contained in the electrical machine.

Example 45E The electrical machine of one or more of the above Eexamples, wherein the at least one switch is a substantial portion ofthe switches contained in the electrical machine.

Example 46E The electrical machine of one or more of the above Eexamples, wherein the at least one switch is all of the switchescontained in the electrical machine.

Example 47E The electrical machine of one or more of the above Eexamples, wherein the at least one rotor is a substantial portion of therotors contained in the electrical machine.

Example 48E The electrical machine of one or more of the above Eexamples, wherein the at least one rotor is all of the rotors containedin the electrical machine.

Example 49E The electrical machine of one or more of the above Eexamples, wherein the plurality of magnets is a substantial portion ofthe magnets contained in the electrical machine.

Example 50E The electrical machine of one or more of the above Eexamples, wherein the plurality of magnets is all of the magnetscontained in the electrical machine.

The present disclosure should be taken to include feasible combinationsof features described herein.

The combination of features described is such as to allow the electricmotor to operate efficiently over a wide power and RPM range and, whererequired, with high power and torque density. Additionally, it permitscombinations of standard components to be assembled together to providea range of electric motor configurations.

The exemplary approaches described may be carried out using suitablecombinations of software, firmware and hardware and are not limited toparticular combinations of such. Computer program instructions forimplementing the exemplary approaches described herein may be embodiedon a tangible, non-transitory, computer-readable storage medium, such asa magnetic disk or other magnetic memory, an optical disk (e.g., DVD) orother optical memory, RAM, ROM, or any other suitable memory such asFlash memory, memory cards, etc.

Additionally, the disclosure has been described with reference toparticular embodiments. However, it will be readily apparent to thoseskilled in the art that it is possible to embody the disclosure inspecific forms other than those of the embodiments described above. Theembodiments are merely illustrative and should not be consideredrestrictive. The scope of the disclosure is given by the appendedclaims, rather than the preceding description, and variations andequivalents that fall within the range of the claims are intended to beembraced therein.

The invention claimed is:
 1. An electrical machine comprising: at leastone module, the at least one module comprising at least oneelectromagnetic coil and at least one switch, the at least one modulebeing attached to at least one stator; at least one rotor with aplurality of magnets attached to the at least one rotor, wherein the atleast one module is in spaced relation to the plurality of the magnets;and an integrated differential coupled to at least one of the at leastone rotors, the at least one integrated differential permitting the atleast one rotor to output at least two rotational outputs tocorresponding shafts, wherein the at least two rotational outputs areable to move the shafts at different rotational velocities relative toone another, wherein the quantity and configuration of the at least onemodule in the electrical machine is determined based in part on one ormore operating parameters; wherein the at least one module is capable ofbeing independently controlled; wherein the at least one module iscapable of being reconfigured based at least in part on one or more ofthe following: at least one operating parameter during operation, atleast one performance parameter during operation, and combinationsthereof; and wherein the electrical machine is configured to beretrofitted into a conventional vehicle by replacing the differential.2. An electrical machine comprising: at least one module, the at leastone module comprising at least one electromagnetic coil and at least oneswitch, the at least one module being attached to the at least onestator; at least one rotor with a plurality of magnets attached to theat least one rotor, wherein the at least one module is in spacedrelation to the plurality of the magnets; and an integrated differentialcoupled to at least one of the at least one rotors, the at least oneintegrated differential permitting the at least one rotor to output atleast two rotational outputs to corresponding shafts, wherein the atleast two rotational outputs are able to move the shafts at differentrotational velocities relative to one another, wherein the quantity andconfiguration of the at least one module in the electrical machine isdetermined based in part on one or more operating parameters; whereinthe at least one module is capable of being independently controlled;wherein the at least one module is capable of being reconfigured basedat least in part on one or more of the following: at least one operatingparameter during operation, at least one performance parameter duringoperation, and combinations thereof; and wherein the electrical machineis configured to be located in substantially that same position where adifferential would otherwise be located in a vehicle or other machine.3. The electrical machine of claim 1, wherein the at least one operatingparameter during operation may be selected from one or more of thefollowing: maximum angular velocity, average angular velocity, minimumangular velocity, maximum power output, average power output, minimumpower output, maximum input voltage, average input voltage, minimuminput voltage, maximum generation voltage, average generation voltage,minimum generation voltage, shape and frequency of generated voltage,peak input current, average input current, minimum input current,maximum generation current, average generation current, minimumgeneration current, maximum torque, average torque, minimum torque,torque smoothness, activation sequence, rate of acceleration, order ofaccuracy of hold angle, minimising the variation of angular velocity,rate of deceleration during breaking, diameter of the shaft, maximumradius of the electrical machine, maximum length of the electricalmachine, maximum depth of the electrical machine, maximum height of themachine, maximum slide distance, minimum slide distance, maximum weightof the machine, minimum weight of the machine, maximum resistive powerloss, and unit redundancy and overall price.
 4. The electrical machineof claim 1, wherein the at least one performance parameter duringoperation may be selected from one or more of the following: maximumangular velocity, maximum power output, deviation from output voltageduring generation, maintaining a required generation voltage, torquesmoothness, rate of acceleration, accuracy of hold angle, minimizing thevariation of angular velocity, matching requested rate of decelerationduring breaking, minimizing resistive power loss, overall efficiency,power factor correction, mechanical harmonic cancelation, electricalharmonic cancelation, accuracy of reproduced output voltage wave andaccuracy of generated frequency.
 5. The electrical machine of claim 1,further comprising at least one sensor to detect absolute or relativeposition of the at least one rotor; and at least one control systemwhich, in response to inputs from the one or more of the following: theat least one sensor, at least one power command, at least one modecommand comprising one or more of the following: at least one drive,generate, braking and hold command, and at least one rotationaldirection command.
 6. The electrical machine of claim 5, wherein the atleast one control system is configured to be in a drive configuration orhas the at least one drive mode command, the at least one control systemactivates the at least one switch which energies one or more of the atleast one electromagnetic coils to attract and repel one or more of theplurality of magnets for the purpose of generating motion.
 7. Theelectrical machine of claim 5, wherein the electrical machine isconfigured to be in a generation configuration or has at least one modecommand to generate power, the at least one control system activates theat least one switch which connects one or more of the at least oneelectromagnetic coils to the external power rails.
 8. The electricalmachine of claim 5, wherein the electrical machine is configured to bein a braking configuration or has the at least one mode command tobrake, the at least one control system activates at least one switchwhich connects one or more of the magnetic coils terminals together tooppose motion.
 9. The electrical machine of claim 5, wherein theelectrical machine is configured to be in a holding configuration or hasthe at least one mode command to hold, the at least one control systemactivates at least one switch which energises one or more of theelectromagnetic coils attract and repel one or more of the plurality ofmagnets for the purpose of stopping motion.
 10. The electrical machineof claim 1, wherein the at least one control system in operation isdetermining one or more appropriately efficient modes of operation inrelation to the at least one operating parameters, the at least oneperformance parameter or combinations thereof on a substantiallycontinuous basis during operating periods.
 11. The electrical machine ofclaim 1, wherein one or more of the at least one operating parameter,the at least one performance parameter or combinations thereof of theelectrical machine may be reconfigured in substantially real time. 12.The electrical machine of claim 1, wherein the module coil activationsequence is computed during machine operation the order of modulesactivating being sequentially based on their geometric position in themodule array.
 13. The electrical machine of claim 1, wherein the modulecoil activation sequence is computed during machine operation, the orderof modules activating being based upon sensor feedback.
 14. Theelectrical machine of claim 1, wherein the module coil activationsequence is computed during machine operation and the order of the atleast one modules activating being determined by at least in part one ormore sequence patterns.
 15. The electrical machine of claim 1, whereinthe total number of the at least one electromagnetic coils powered inthe active sequence may vary during operation from the total number ofcoils, to none.
 16. The electrical machine of claim 1, wherein thecontrol of the electrical machine is centralized on at least one controlmodule.
 17. The electrical machine of claim 1, wherein one or moremodules of the at least one module may be individually removed, added,or replaced during operation of the machine, without substantiallyaffecting the operational state of the machine.
 18. The electricalmachine of claim 1, wherein the at least one module is capable of beingreconfigured based at least in part on one or more of the following: atleast one operating parameter during operation, wherein the at least oneoperating parameter during operation may be selected from one or more ofthe parameters listed in claim 3, at least one performance parameterduring operation, wherein the at least one performance parameter duringoperation may be selected from one or more of the parameter listed inclaim 4; or combinations thereof.
 19. The electrical machine of claim 1,wherein the electrical machine is a compact direct drive electric motorthat generates sufficient or improved propulsion in a wheeled vehicleand the electric motor and the differential can fit the size of envelopeof existing differentials in a conventional combustion engine drivenvehicle.